TM

Magnum Monosteel Piston

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

• The Monosteel Piston pioneered an innovative

friction welding process to join the piston head and
skirt,, enabling
g optimum
p g
gallery
y designs
g for both
efficient oil cooling and maximum strength

• Over 3.5 million Monosteel Pistons have now been

produced; annual production by 2012 will exceed
1 5 million
1.5 illi

• 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

• The Monosteel Piston was awarded a prestigious

Automotive News PACE Award in 2006
Federal-Mogul Corporation Public October 2
Heavy-Duty
y y Piston Market Evolution
Monosteel®
250
240 bar!
A ti l t d
Articulated

220
220
Aluminum
200

180 180

160 160

140
130
110
120 bar

1960 1970 1980 1990 2000 2010 2020

Years
Federal-Mogul Corporation Public October 3
Monosteel® Technology
gy Evolution

Original Monosteel® Next generation Future Monosteel®

with bushing – first Monosteel® bushingless, Magnum, bushingless,
production MnP coated pin MnP coated pin bores

2003 2005 2012

Federal-Mogul Corporation Public October 4

High PCP Piston Architecture
Steel Piston – Enabling Technology
Monosteel Piston Box Structure Gallery Design
• The welded closed gallery design significantly increases the structural strength
of the piston,
piston improves fatigue safety factor (SF) and stability of the ring belt
Unsupported ring belt Monosteel®

SF=1 4
SF 1.4 SF>5

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

Federal-Mogul Corporation Public October 5

High Combustion Temperature
Steel 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,
piston resulting in significant piston temperature reductions
reductions.
Other Piston Monosteel®

Top groove Bowl rim Top groove Bowl rim

282°C 485°C Δ20-60°C Δ50-100°C

Undercrown Undercrown
309°C Δ20-40°C

Federal-Mogul Corporation Public October 6

Monosteel®
Technology Evolution - Magnum
Key features include:
• Double-band
Double band piston skirt design
design, 50

a first for modern diesel pistons 40

Fricttion Loss, kW
production
30
• Dual friction-welded construction, 20
enablingg large
g cooling
gggalleries for 10
Magnum Monosteel

high-temperature resistance and

0
strength 1000 1200 1400 1600 1800
Engine Speed, rpm
• Friction reduction of 17 percent, 15L Diesel, Willans Line test results

when
h compared d tto conventional
ti l
steel piston designs

• Reciprocating mass reduction of up

to 7%

• On test with major engine

manufacturers in the U.S. and Europe

Federal-Mogul Corporation Public October 7