Materials and Manufacturing processes of engine components

In summary, the team is having difficulty determining the materials used and the manufacturing processes for critical engine components. They have tried contacting Ford but have not been successful. If anyone has prior experience in forging and casting engine components, your help would be greatly appreciated.
  • #1
JLB4344
2
0
Hi, i am new to this forum and have just moved onto the second year of my BEng mechanical degree programme.We have been given the task of reverse engineering a 1.4l ford zetec s engine from a 1995/1997 fiesta.

The problem we are having is identifying the materials used and the manufacturing processes of critical components. We have tried contacting Ford but understandably they will not realease to us the alloys used to make their components. If there is anybody with prior experince in forging and casting engine components your help would be greatly appreciated.

So far we have carried out Vickers hardness tests on the camshaft, conrod, valves, shim and piston head. In the hope to determine the materials used and their finishes but can't find anywhere to look these values up against different metals and alloys.

If anyone can shed some light on the critical components such as the valve train, cylinder head, engine block, conrod or piston head, this would be welcome.

Thanks
John
 
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  • #2
Have you measured volume (by immersion) and mass, with which one can determine the density of the various components. One could also try to measure magnetic propreties.

Perhaps your department could invest in a portable analyzer which uses X-ray fluorescence to analyze elements in alloys. Something like -
http://www.oxinst.com/wps/wcm/connect/Oxford+Instruments/Products/X-ray+Fluorescence/X-MET3000TX/X-MET3000TX :biggrin:


http://www.zetecinside.com/xr2/specification.htm (nit much detail on alloy composition).

If you contacted Ford US - forget it. However, you might try contacting folks at Bridgend engine plant in Wales. :biggrin:

Try this - http://en.wikipedia.org/wiki/Ford_Zetec_engine
 
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  • #3
The manufacturing processes for the parts you listed are pretty basic. For example, the cam shafts are cast, then lathe turned and then ground. I am sure you should be able to find information on the pasic processes without too much trouble. The tough part, as you have found out, will be in material selections and tratments, etc... That is where you start to get into the proprietary end of things. If you had access to a metalurgical lab, you could do tensile tests and etchings to get estimates of properties and the grain structures could point the way to certian heat treats. Other than that, I don't see how you could get that in fo without the OEM telling you.
 
  • #4
Cheers guys now have several sections of components mounted in bakelite and waiting to be etched before they go under the microscope.
 

Related to Materials and Manufacturing processes of engine components

1. What materials are commonly used in engine components?

The most commonly used materials in engine components are metals such as steel, aluminum, and titanium. These materials are chosen for their strength, durability, and heat resistance.

2. What is the manufacturing process for engine components?

The manufacturing process for engine components typically involves casting, machining, and heat treatment. First, the desired shape of the component is cast using molten metal. Then, it is machined to achieve the desired dimensions and surface finish. Finally, the component undergoes heat treatment to improve its strength and hardness.

3. How are engine components tested for quality control?

Engine components undergo various tests for quality control, including dimensional inspection, material testing, and performance testing. Dimensional inspection ensures that the component meets the desired specifications, while material testing checks for any defects or impurities. Performance testing involves running the component under simulated operating conditions to ensure it functions properly.

4. What are some common defects found in engine components?

Common defects found in engine components include cracks, voids, and porosity in the metal. These defects can weaken the component and affect its performance. Other defects may include incorrect dimensions, surface imperfections, or improper heat treatment.

5. How are new materials and processes being developed for engine components?

New materials and processes for engine components are constantly being developed to improve performance, efficiency, and durability. This involves extensive research and testing to find new materials with better properties, as well as developing new manufacturing techniques such as 3D printing and advanced machining methods.

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