CASE STUDY

Aluminum Alloy Revolutionizes Cam Caps for Automotive Manufacturer

WHO

An Automotive Original Equipment Manufacturer (OEM)

THE CHALLENGE

A design release engineer from a large automotive manufacturer approached MPP at a critical time. The customer was developing a new start-stop SUV engine. The start-stop feature in their new engine, while beneficial for fuel efficiency, posed a problem. With each stop, the engine, along with its oil pump, faced a moment of no active lubrication. This increased the wear on critical components, such as cam caps and the engine. The engineer turned to MPP for a solution to develop cam caps from a new, wear-resistant alloy.

WHO

An Automotive Original Equipment Manufacturer (OEM)

THE CHALLENGE

A design release engineer from a large automotive manufacturer approached MPP at a critical time. The customer was developing a new start-stop SUV engine. The start-stop feature in their new engine, while beneficial for fuel efficiency, posed a problem. With each stop, the engine, along with its oil pump, faced a moment of no active lubrication. This increased the wear on critical components, such as cam caps and the engine. The engineer turned to MPP for a solution to develop cam caps from a new, wear-resistant alloy.

THE SOLUTION

MPP embarked on an intensive research and development journey, crafting three distinct alloy compositions and subjected them to testing. After evaluation, aluminum emerged as the alloy of choice in its promise for durability and wear resistance. The aluminum alloy has a specialized microstructure that uses nanotechnology to increase the wear resistance to levels far above normal aluminum alloys. MPP collaborated closely with the customer’s engineers to ensure a seamless integration of the new cam caps into their engine design.

New High Wear Resistance MPP aluminum alloy
MPP Alloy Designation:-  AC-4144 T2, nominal Al-8%Si.
English Units Metric Units
UTS
24,000 psi
165 MPa
Yield Strength
21,000 psi
145 MPa
Elongation
1%
1%
Hardness
5 HRB
5 HRB
THE IMPACT

The customer confirmed through multiple life tests that the cam caps exceeded the longevity and reliability requirements of their new engine. In fact, after multiple life tests, MPP’s cam caps were measured and found to have no material loss due to wear. With MPP's expertise and timely production, the customer successfully launched their engine on schedule, with the capability to produce a staggering 30 million cam caps annually. This achievement addressed the immediate challenge of wear in start-stop engines and enhanced structural stability.

30 MILLION
annual production capability
Developing custom high-performance alloys tailored to meet your engine's strength and wear requirements, driving towards your mpg goals and beyond.

MPP stands as the premier  aluminum parts maker, equipped with cutting-edge production and blending capabilities.