Weight and Cost Reduction — Engine and Engine Components — Converting Castings to Stampings

This paper describes a conceptual development program to demonstrate the weight and cost reduction potential using steel stampings for internal combustion engines and engine components. Various components have been redesigned as steel stampings to replace cast iron or cast aluminum items on a weight and/or cost reduction basis.

Designs of a stamped steel engine block, intake and exhaust manifolds, water pump, power steering pump, pulleys, alternator and turbocharger housing are described. Stamped steel versions which have been prototyped and tested are described.

A review of current applications and suggested applications of stampings to replace castings concludes the paper.