Evolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron liners

To minimize the carbon footprint of transportation industry, manufacturers and engineers are continuously trying to improve efficiency combustion engine. However, due presence iron cylinder liners in engine block, high tensile residual stresses generated during manufacturing process which leads a large reduction alloy’s useable strength. Thus, present study utilized neutron diffraction study, for first time, evolution stress sand-cast aluminum blocks that have eliminated from casting mechanically inserted them after heat treatment machining operations. Moreover, this also examined effects bore chills on resulting profiles. The replacement shifted mode purely tension compression until were removed. Following removal chills, maximum at top bridge was ~ 70% lower than engine’s predecessor produced with liners. production-ready state (i.e., T7 treated press-fit inserted), maintains partially compressive nature, thereby lowering material’s susceptibility crack growth propagation.