Ford + carbon fibre = engine!

[Mr Brooksy]

http://www.topgear.com/car-news/detr...coboost-engine

Meet Ford’s carbon-fibre EcoBoost engine
Jack Rix
11 Jan 2016

We’ve seen carbon-fibre body panels, tubs and even wheels – now meet the carbon-fibre engine.

Manufacturers are already OCD about stripping weight from a car’s chassis, body and interior by using exotic materials, but why not the engine itself? Obvious, isn’t it. Well, Ford has had a go and the results are not to be sniffed at.

Based on its diddiest little 1.0 EcoBoost unit – yep, the one that accounted for 50 per cent of Fiesta sales in the UK last year – the prototype engine was shown sliced in half at the Detroit show.

Engineers focused on five main components: the cylinder block, cylinder head, connecting rods, front cover and oil pan resulting in an overall weight saving of 15.5 per cent - or 13kg. Doesn’t sound like much, we know, but Ford claims an improvement in fuel economy of around 4.5 per cent. Oh, you’re listening now.

While the front cover, oil pan and cam-carrier are all made from injection-moulded carbon-fibre, the connecting rods are actually switched to forged aluminium and the cylinder block to aluminium with powder metal inserts on the important load paths.

Question is, when can you buy one fitted to your Fiesta or Focus? Well, Ford wouldn’t commit to a date, but the technology is complete and works like a dream. The key is putting the injection-moulded carbon-fibre into mass production, thus eliminating the labour element and instantly driving costs through the floor.

So, what do we think – could this be the technology that helps us enjoy the combustion engine for a little longer?

No, the whole motor is not carbon fibre, that is not possible at least as far as I've heard, but F1 and WEC have had CF parts as part of their engines for a while. However for the auto industry, these things start to make some serious sense as CF production is becoming more and more cost effective especially in mass production.

My questions for CF to find it's way into engine components are, 1) speed of production has got to be much longer than casting, pressing or even moulding; 2) strength over the life of the car especially a component like the oil pan where the temps rise and fall consistently...

But it's an interesting step by an otherwise recently conservative auto maker!

[Kable72]

That's interesting. How does CF go with the heat?

[Mr Brooksy]

Originally Posted by Kable72

That's interesting. How does CF go with the heat?

I only know that in F1, they use as much CF in non critical components as possible (critically components are like most internals). But then again F1 engine rev higher (more so in the V8, V10 era's) and are under much higher strain. They don't however need to run for 300,000km+.

Kable, it would be interesting to see...

[Tocchi]

koenisesigg (spelling?) in the early days ran a ford modular engine (modified of course) and was mostly carbon fibre components on said engine

[data_mine]

Originally Posted by Kable72

That's interesting. How does CF go with the heat?

See many melted diamonds?

the carbon fibre itself melt point of about 3500°, so it's fine.

The resin used to bind it, is what you need to concentrate on. The epoxies go to 300 odd degrees.

But if they really wanted high temp and strength, look at carbon ceramic brakes. Carbon fibre in a ceramic binder (instead of the epoxy).

I for one welcome our new carbon fibre overlords.

[mik]

So many good ideas for stuff , its good ford is experimenting on possible new technology .

if it was to end up on the production line what will be cost effect ? longevity ?

[pauljh74]

Originally Posted by Kable72

That's interesting. How does CF go with the heat?

They use it in brakes in F1 because they're better at handling high heat. Carbon Ceramic is used in performance road cars because full CF doesn't stop too well when it is relatively cold.

[data_mine]

Originally Posted by Tocchi

koenisesigg (spelling?) in the early days ran a ford modular engine (modified of course) and was mostly carbon fibre components on said engine

Check this video (from about 26mins in), the motors use carbon for trim, not integral parts.
https://youtu.be/71wvtEZ-jcI

Still look a lot like a mod motor though.

[Burnout]

The new Cumins engine, for use in Trucks etc. is a composite block. Big weight loss compared to the previous ISX.