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A study is presented in which light-weight composite materials are used for an engine intake valve. This paper is an interim progress report and documents the successful demonstration of a net-shape, resin transfer molded intake valve in a running engine. A short review of a previous dynamic model is presented showing the advantages in engine performance by using the composite valves. It is shown that the use of reduced mass composite valves allows for increased engine speed and/or more aggressive cam profiles without sacrificing valve strength or stiffness while at the same time maintaining reliable operation. The use of composite materials allows for a significant weight reduction compared to more conventional materials such as steel and titanium. A brief review of the use of composite materials is presented. The development and design process for carbon fiber reinforced valves is discussed.

Fiber Reinforced Composites (FRCs) offer the possibility for reduced mass and increased performance in internal combustion engines, yet the automotive and aerospace industries have been slow to adopt these materials. Extensive research has been done over the past 25 years, producing nearly every components of an internal combustion engine out of some form of FRC. This Previous work is summarized herein. A prediction of engine weight reduction is made for direct substitution of FRCs. An additional prediction is made to quantify the additive effects of mass reduction on component mass, and power. It is estimated that engine mass might be reduced by as much as 70% using FRCs and reciprocating mass might be reduced by as much as 90%. In addition, increased mechanical efficiency on the order of 2% may be possible from reduced inertial and frictional loads.