MAHLE TopWeld steel piston for high-speed diesel applications. 2-5% CO2 reduction compared to aluminum pistons.

The lower thermal expansion of steel compared to aluminum results in a significant lower friction between the piston and the cylinder liner. Under temperature load there is still a remaining running clearance between cylinder and steel piston. Using the aluminum piston there is an overlap due to the thermal expansion of the piston.

The higher strength of steel permits a significant reduction of the compression height and in total a lower weight of the piston assembly compared to an aluminum piston assembly.

The lower compression height allows the usage of a longer con-rod. This has a positive effect on the maximum side forces and because of this directly a positive influence on the friction losses. When using the original con-rod length, it is possible to decrease the engine height. This results in potential lower air resistance of the vehicle or in a better behavior in terms of pedestrian protection.

In summary, the new TopWeld piston design achieves 2-5% CO2 reduction due to lower friction because of no thermal overlap and reduced side forces. In addition a weight reduction of the piston assembly due to the higher strength of steel provides the opportunity to reduce the friction losses and the mass not only of the piston but also of the whole engine by reducing the counterweights of the crankshaft and the bearing loads.

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MAHLE is a leading international development partner and supplier to the automotive industry as well as a pioneer for the mobility of the future. The MAHLE Group is committed to making transportation more efficient, more environmentally friendly, and more comfortable by continuously optimizing the combustion engine, driving forward the use of alternative fuels, and laying the foundation for the worldwide introduction of e-mobility.

The group’s product portfolio addresses all the crucial issues relating to the powertrain and air conditioning technology—both for drives with combustion engines and for e-mobility. MAHLE products are fitted in at least every second vehicle worldwide. Components and systems from MAHLE are also used off the road—in stationary applications, for mobile machinery, rail transport, as well as marine applications.

Our videos include the following subjects: Automobile, Cars, Motorsport, Piston, Valve, Compressor, Engine, Connecting Rod, Turbocharger & Filter.

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