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The Reynolds’ 390 engine technology eliminates the need for iron bore liners in aluminum engines. This allows casting of the cylinder block and bores as an integral unit. The technology is a three-part system consisting of the hypereutectic 390 aluminum-silicon alloy, compatible pistons and a special cylinder bore finish. When properly applied, it can produce a lightweight, strong, compact and relatively low-cost aluminum engine block.

High integrity aluminum castings are potential replacements for cast iron in current vehicle weight reduction programs. Domestically, several cast aluminum structural-type components are already realities, saving weight and contributing to improved fuel economy; wheels, brake drums, master brake cylinders and power steering housings. In Europe, suspension components, wheel hubs and disc brake calipers are cast in aluminum for some car models, indicating the functional and economic feasibility of such parts. Alloy and process technology already exist to enable production of realiable, high strength aluminum castings. Domestic automotive product engineers are urged to carefully consider and thoroughly test such aluminum castings along with the many other weight reduction possibilities currently being investigated.

Aluminum castings have much to offer the automotive industry in terms of weight reduction and energy savings. Their long-term acceptability can only be assured, however, by applying the most cost-effective combinations of material and processing. This paper will point out some “cost-saving” opportunities in two basic areas: (1) The use of hypereutectic aluminum-silicon alloys to eliminate a need for ferrous wear-surface inserts, to reduce machining capital expenditures and to reduce overall part weight; and (2) The use of two processing methods, “Pore-Free” die casting and “low-pressure” casting, to produce aluminum parts with minimum metal usage and energy consumption.