Cosworth Collaborates with Materion

Cosworth Collaborates with Materion

By Manufacturing Technology Insights | Tuesday, February 16, 2021

Cosworth widens its industry-leading range of pistons through a partnership with advanced materials supplier, Materion.

FREMONT, CA: Global technology firm Cosworth widens its industry-leading range of pistons through a partnership with advanced materials supplier, Materion, which sees Cosworth produce and machine Metal Matrix Composite (MMC) pistons for the automotive sector. Cosworth's MMC pistons have already assisted in offering excellent performance in the all-new Gordon Murray Automotive T.50 supercar, which boasts a maximum speed of 12,000rpm and creates the highest specific output of any roadgoing aspirated engine at 166PS-per-litre.

Underpinning Cosworth's reputation, its MMC pistons' inclusion in the Lanzante TAG Turbo project, changing historic podium winning F1 engines into usable, roadgoing vehicles. Cosworth's wealth of knowledge in piston development and manufacture has long positioned the firm as the first port-of-call for many OE manufacturers. With the rising demand for high-level components, the firm took steps to ensure that its reputation was strengthened with its solutions. Working with Materion, Cosworth's move to Metal Matrix Composites has enabled the company to move away from the conventional metal billets, forgings, and castings that are not suited to the requirements of tomorrow's high-performance engines.

Materion's SupremEX composite couples ultrafine silicon carbide reinforcement with aerospace aluminum alloys. The outcome is a composite that is superior to conventional alloys, integrating aluminum's lightweight properties with outstanding strength and stiffness. SupremEX pistons can be leveraged to replace aluminum, titanium, steel, and other alloys and composites. The stiffness of SupremEX exceeds that of piston materials by at least 40 percent, enabling a significant reduction in reciprocating mass.

MMC pistons' reinforced structure reduces wear at critical interfaces, compared to conventional aluminum piston alloys, for example, and provides a 25 percent lower coefficient of thermal expansion. This, in turn, lets tighter control of piston to liner clearance mitigating piston slap, blow-by-oil carry over, and crevice volume, offering increased efficiency. Higher temperatures and combustion pressures can be attained due to greater fatigue resistance with a lower friction coefficient and increased wear resistance contributing to enhanced combustion efficiency, fuel consumption, and hydrocarbon emissions.

The MMC pistons are vital components that have allowed Cosworth to engineer like advanced lightweight V12 engine for the GMA T.50. The pistons are vital to the engine's potential to hit a maximum speed of 12,000rpm and produce the highest specific output of any roadgoing naturally aspirated engine at 166PS-per-litre.

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