Cylinder Block and Head Materials and Manufacturing

  • Kevin Hoag
  • Brian Dondlinger
Part of the Powertrain book series (POWERTRAIN)


Before addressing cylinder block and head layout design it is important to understand the restrictions imposed by material and casting process selection. This chapter begins with a brief look at the aluminum and gray iron alloys typically used for cylinder blocks and heads. Magnesium alloys, and composite blocks with magnesium portions are receiving increased attention for weight reduction, and will also be briefly covered. Many of the design constraints are imposed by the capabilities of the chosen casting process, so the commonly used casting processes will next be introduced. The chapter concludes with an overview of the machining lines used for block and head production.


Casting Process Ductile Iron Cylinder Head Graphite Flake Gray Iron 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.


  1. Baril, E., Labelle, P., Fischersworring-Bunk, A.: AJ (Mg-Al-Sr) Alloy System Used for New Engine Block. SAE 2004-01-0659 (2004)Google Scholar
  2. Dawson, S.: Compacted Graphite Iron—A Material Solution for Modern Engine Design. SAE 2011-01-1083 (2011)Google Scholar
  3. Gervin, S.J.: Cast Metals Technology. American Foundry Society, Des Plaines (1995)Google Scholar
  4. Kurita, H., Yamagata, H., Arai, H., Nakamura, T.: Hypereutectic Al-20 %Si Alloy Engine Block Using High-Pressure Die-Casting. SAE 2004-01-1028 (2004)Google Scholar
  5. Pedersen, A.S., Fischersworring-Bunk, A., Kunst, M., Bertilsson, I., de Lima, I., Smith, M.: Light Weight Engine Construction through Extended and Sustainable Use of Mg-Alloys. SAE 2006-01-0068 (2006)Google Scholar
  6. Powell, B.R., Ouimet, L.J., Allison, J.E., Hines, J.A., Beals, R.S., Kopka, L., Ried, P.P.: Progress Toward a Magnesium-Intensive Engine: The USAMP Magnesium Powertrain Cast Components Project. SAE 2004-01-0654 (2004)Google Scholar
  7. Takami, T., Fujine, M., Kato, S., Nagai, H., Tsujino, A., Masuda, Y.-h., Yamamoto, M.: MMC All Aluminum Cylinder Block for High Power SI Engines. SAE 2000-01-1231 (2000)Google Scholar
  8. Warrick, R.J., Ellis, G.G., Grupke, C.C., Khamseh, A.R., McLachlan, T.H., Gerkits, C.: Development and Application of Enhanced Compacted Graphite Iron for the Bedplate of the New Chrysler 4.7 Liter V-8 Engine. SAE 1999-01-0325 (1999)Google Scholar
  9. Yamazaki, M., Takai, A., Murakami, O., Kawabata, M.: Development of a High-Strength Aluminum Cylinder Block for Diesel Engine Employing a New Production Process. SAE 2004-01-1447 (2004)Google Scholar

Copyright information

© Springer Vienna 2016

Authors and Affiliations

  1. 1.Southwest Research InstituteSan AntonioUSA
  2. 2.MilwaukeeUSA

Personalised recommendations