Replacement of gasoline engines in light trucks with diesel engines would reduce US transportation energy use by more than 15 percent with comparable reduction in emissions. Engine weight is a major hurdle, with aluminum being the desired material, over the current iron. However, aluminum castings currently lack required stiffness and strength at operating temperatures.
Foster-Miller completed a program for the US Army Tank and Automotive Command (TACOM) partnering with a major engine manufacturer and castings producer. Combustion plates were produced from aluminum castings reinforced with metal-matrix composites (MMC). Strength and modulus for our material was nearly double that of the iron standard at normal operating temperatures, while weight was about half. Additional follow-on work with DOE will produce and test a full-scale medium-duty aluminum diesel engine head casting.
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