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The MuCell® microcellular foam injection molding process is being applied by the world's leading automotive components manufacturers as a core plastics manufacturing technology to achieve (1) higher productivity, (2) vehicle weight reduction, (3) quality improvement, and (4) cost savings. The microcellular foam injection molding process results in automotive components that are lighter, flatter, straighter, and more dimensionally stable at extreme operating temperatures compared to conventionally molded parts. The process uses supercritical fluids (SCF) of inert gases, typically nitrogen or carbon dioxide, to create evenly distributed and uniformly sized microscopic cells throughout a polymer. Suitable for injection molding (as well as extrusion and blow molding), the microcellular foam process enhances product design, improves processing efficiency, and reduces product costs.

The first easily injection moldable and recyclable polyimide components are experiencing fast growth within the automotive industry as ultra-high performance and cost-effective replacements for metals and conventional polyimides in high heat and demanding wear applications. Offering exceptional PV capability in lubricated and dry environments, low wear factors and coefficients of friction, high strength and toughness, and continuous operating performance at 550 °F, thermoplastic polyimide components (TPI) have entered critical applications such as transmission seal rings and thrust washers, engine and turbocharger bearings, and bearings and bushings for steering and suspension systems, electric motors, and HVAC. Unlike injection molded TPI, conventional polyimide components are non-recyclable and are limited to compression molding and sintering fabrication with inherent cost and performance drawbacks.

ALUMINUM engines promise a gain in the power/weight ratio and possibilities of production economies. Aluminum has already proved its value for some parts; only the adaptation of design for high production methods delays full realization of the metal's potentials. This paper describes the problems encountered in adapting the V-type engine to fabrication methods using aluminum alloy parts. Applications of aluminum in crankcase and cylinder block, cylinder liners and heads, intake manifold, pistons, and bearings are also discussed.