Abstract: The invention relates to a method for producing an engine component, in particular a piston for an internal combustion engine, wherein an aluminum alloy is cast in the gravity die casting process and wherein the aluminum alloy has 7 to <14.5 wt % silicon, >1.2 to ?4 wt % nickel, >3.7 to <10 wt % copper, <1 wt % cobalt, 0.1 to 1.5 wt % magnesium, 0.1 to ?0.7 wt % iron, 0.1 to ?0.7 wt % manganese, >0.1 to <0.5 wt % zirconium, ?0.1 to ?0.3 wt % vanadium, 0.05 to 0.5 wt % titanium, and 0.004 to ?0.05 wt % phosphorus as alloying elements and aluminum and unavoidable contaminants as the remainder. The aluminum alloy can optionally comprise beryllium, wherein the calcium content is limited to a low level.

Abstract: A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

Abstract: A method for producing an engine component, more particularly a piston for an internal combustion engine, in which an aluminum alloy is cast using the gravity die casting method is provided. The aluminum alloy comprises: 9 to ?10.5% by weight silicon, >2.0 to <3.5% by weight nickel, >3.7 to 5.2% by weight copper, <1% by weight cobalt, 0.5 to 1.5% by weight magnesium, 0.1 to 0.7% by weight iron, 0.1 to 0.4% by weight manganese, >0.1 to <0.2% by weight zirconium, >0.1 to <0.2% by weight vanadium, 0.05 to <0.2% by weight titanium, 0.004 to 0.008% by weight phosphorus, with aluminum and unavoidable impurities constituting the rest. An engine component, in particular a piston, wherein the engine component consists, at least partially, of the aluminum alloy, and the use of an aluminum alloy to produce the engine component, is also provided.

Abstract: A method is described for producing an engine component, more particularly a piston for an internal combustion engine, in which an aluminium alloy is cast using the gravity die casting method and wherein the aluminium alloy comprises the following alloy elements: 9 to ?10.5% by weight silicon, >2.0 to <3.5% by weight nickel, >3.7 to 5.2% by weight copper, <1% by weight cobalt, 0.5 to 1.5% by weight magnesium, 0.1 to 0.7% by weight iron, 0.1 to 0.4% by weight manganese, >0.1 to <0.2% by weight zirconium, >0.1 to <0.2% by weight vanadium, 0.05 to <0.2% by weight titanium, 0.004 to 0.008% by weight phosphorus, wherein said aluminium alloy further comprises aluminium and unavoidable impurities.

Abstract: A method for producing an engine component, more particularly a piston for an internal combustion engine, in which an aluminium alloy is cast using the gravity die casting method is provided. The aluminium alloy comprises: 9 to ?10.5% by weight silicon, >2.0 to <3.5% by weight nickel, >3.7 to 5.2% by weight copper, <1% by weight cobalt, 0.5 to 1.5% by weight magnesium, 0.1 to 0.7% by weight iron, 0.1 to 0.4% by weight manganese, >0.1 to <0.2% by weight zirconium, >0.1 to <0.2% by weight vanadium, 0.05 to <0.2% by weight titanium, 0.004 to 0.008% by weight phosphorus, with aluminium and unavoidable impurities constituting the rest. An engine component, in particular a piston, wherein the engine component consists, at least partially, of the aluminium alloy, and the use of an aluminium alloy to produce the engine component, is also provided.

Abstract: A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

Abstract: A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

Abstract: The invention relates to a method for producing an engine component, in particular a piston for an internal combustion engine, wherein an aluminum alloy is cast in the gravity die casting process and wherein the aluminum alloy has 7 to <14.5 wt % silicon, >1.2 to ?4 wt % nickel, >3.7 to <10 wt % copper, <1 wt % cobalt, 0.1 to 1.5 wt % magnesium, 0.1 to ?0.7 wt % iron, 0.1 to ?0.7 wt % manganese, >0.1 to <0.5 wt % zirconium, ?0.1 to ?0.3 wt % vanadium, 0.05 to 0.5 wt % titanium, and 0.004 to ?0.05 wt % phosphorus as alloying elements and aluminum and unavoidable contaminants as the remainder. The aluminum alloy can optionally comprise beryllium, wherein the calcium content is limited to a low level.

Abstract: A method is described for producing an engine component, more particularly a piston for an internal combustion engine, in which an aluminium alloy is cast using the gravity die casting method and wherein the aluminium alloy comprises the following alloy elements: 9 to ?10.5% by weight silicon, >2.0 to <3.5% by weight nickel, >3.7 to 5.2% by weight copper, <1% by weight cobalt, 0.5 to 1.5% by weight magnesium, 0.1 to 0.7% by weight iron, 0.1 to 0.4% by weight manganese, >0.1 to <0.2% by weight zirconium, >0.1 to <0.2% by weight vanadium, 0.05 to <0.2% by weight titanium, 0.004 to 0.008% by weight phosphorus, wherein said aluminium alloy further comprises aluminium and unavoidable impurities.

Abstract: A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.