Magnum MonosteelTM Piston

Monosteel®

• First production of the Monosteel Piston for a heavy-duty commercial customer diesel engine in 2003in 2003

• The Monosteel Piston pioneered an innovative friction welding process to join the piston head and skirt, enabling optimum gallery designs for both , g p g y gefficient oil cooling and maximum strength

• Over 3.5 million Monosteel Pistons have now been produced; annual production by 2012 will exceed 1 5 illi1.5 million

• Current customers include major U.S., European and Korean commercial vehicle engine manufacturers

• Euro 6 and Tier 4 emissions regulations place a premium on enabling technologies for strength, cooling, and fuel economy improvement

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• The Monosteel Piston was awarded a prestigious Automotive News PACE Award in 2006

Heavy-Duty Piston Market Evolution

A ti l t d

Monosteel®

240

y y

250bar!

Aluminum

Articulated

220 220Aluminum

200

180 180

160

140

160

140

120130110

bar

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Years1970 1980 1990 2000 2010 20201960

Monosteel® Technology Evolutiongy

® ®Original Monosteel®with bushing – first production

2003

Next generation Monosteel® bushingless, MnP coated pin

2005

Future Monosteel®Magnum, bushingless, MnP coated pin bores

20122003 2005 2012

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High PCP Piston ArchitectureSteel Piston – Enabling Technology

• The welded closed gallery design significantly increases the structural strength of the piston improves fatigue safety factor (SF) and stability of the ring belt

Monosteel Piston Box Structure Gallery Design

of the piston, improves fatigue safety factor (SF) and stability of the ring beltUnsupported ring belt Monosteel®

SF=1 4 SF>5SF 1.4 SF>5

• Crack-free piston

• High-safety factors determined by finite element analysis (FEA)Low-life prediction = Crack!

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by finite element analysis (FEA)p

High Combustion TemperatureSteel Piston – Enabling Technology

Monosteel Piston Cooling Gallery Design• The two-piece welded piston design allows the cooling gallery to be closer to

the top of the piston resulting in significant piston temperature reductions

Other Piston Monosteel®the top of the piston, resulting in significant piston temperature reductions.

Top groove Bowl rim Top groove Bowl rimTop groove282°C

Bowl rim485°C

Top grooveΔ20-60°C

Bowl rimΔ50-100°C

Undercrown Undercrown

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309°C Δ20-40°C

Monosteel®

Technology Evolution - MagnumTechnology Evolution - Magnum

• Double-band piston skirt design 50

Key features include:

Double band piston skirt design, a first for modern diesel pistons

• Dual friction-welded construction, enabling large cooling galleries for

50

40

20

30

10tion

Loss

, kW

Magnum Monosteel

production

g g g ghigh-temperature resistance and strength

• Friction reduction of 17 percent, h d t ti l

10

10000

1200 1400 1600 1800Engine Speed, rpm

Fric

t

15L Diesel, Willans Line test results

when compared to conventional steel piston designs

• Reciprocating mass reduction of up to 7%to 7%

• On test with major engine manufacturers in the U.S. and Europe

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