Hybrid Piston Structure for Strength and Cooling Channel Geometry
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing piston production methods using additive hardening for high-load regions result in lower strength, leading to increased weight and fuel consumption, as conventional methods struggle to achieve complex geometries and efficient heat transfer.
Innovation Solution
Producing pistons with a forged or cast upper part for high-load regions and an additively manufactured lower part, allowing for complex geometries and improved heat transfer through additive methods like laser melting, while saving material in less stressed areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive hardening method is used for piston upper part, then complex geometries can be achieved, but strength is reduced
Solution Approach 1:
The piston is divided into two parts: the piston upper part (subjected to high thermal and mechanical loads) is produced by conventional casting or forging methods to ensure high strength, while the piston lower part (subjected to lower loads) is produced by additive manufacturing methods to achieve complex geometries and weight reduction. This segmentation allows each part to be optimized for its specific requirements.
2Strength
If piston is designed stronger to compensate for additive method weaknesses, then strength is improved, but weight increases
Solution Approach 1:
Different regions of the piston are assigned different material properties and production methods based on their functional requirements. The piston upper part uses conventional manufacturing to achieve high strength where needed, while the piston lower part uses additive manufacturing with optimized lattice structures or thin-walled designs to reduce weight in regions where full strength is not required.
3Strength
If conventional casting or forging is used, then strength is achieved, but complex geometries and efficient heat transfer are difficult to obtain
Solution Approach 1:
The piston is divided into two parts: the piston upper part (subjected to high thermal and mechanical loads) is produced by conventional casting or forging methods to ensure high strength, while the piston lower part (subjected to lower loads) is produced by additive manufacturing methods to achieve complex geometries and weight reduction. This segmentation allows each part to be optimized for its specific requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances strength in high-load regions, improves heat transfer, and reduces weight by utilizing additive manufacturing for lower-load areas, enabling more efficient engine operation.
Implementation Method 1
the part of the cooling channel which is arranged in the piston upper part is closed by means of an additive method, e.g. by means of laser melting or laser sintering
Data Source
AI summary
A method for producing a piston for an internal combustion engine may include producing a piston upper part including a piston top, at least parts of a ring section, and at least part of a cooling channel, producing a piston lower part and closing the part of the cooling channel arranged in the piston upper part via an additive method, and finish-machining the piston. Finish-machining the piston may include producing at least one annular groove in a ring support for receiving a piston ring.