R - Hastings

WHO WE AREFor nearly 100 years Hastings Manufacturing, based inHastings, Michigan USA, has been serving the internalcombustion industry with the design and manufactureof high-quality piston rings that improve combustionefficiency and reduce oil consumption.EXECUTIVE TEAM800-776-1088 • www.hastingsmfg.comFrederick A. Cook, Jr.President & CEOOver 28 years ofmanufacturing, design,and managementexperience includinglinear motion ball bearingsand 2-cycle engines.Richard L.Zwiernikowski, Jr.CFOOver 18 years withHastings ManufacturingCompany—responsiblefor internal and externalfinancial reporting andoverall bottom line.Jeffrey P. GuentherDirector of Sales& MarketingOver 23 years withHastings ManufacturingCompany establishingaftermarket sales,marketing, anddistribution worldwide.Christopher K. HafkeDirector of DevelopmentOver 22 years of OEMengineering, manufacturing,and management experiencein Tier One Automotive withFortune 500 companiesincluding 10 years of engineparts experience.Robert M. KollarDirector of CustomerSatisfactionOver 30 years of productionmanagement with customerfocuseddirection includingthree time winner of GMSupplier of the Year award.Michael A. TomkoDirector of OperationsOver 12 years ofTier One automotiveoperations managementexperience includingdiverse product andprocess control.

OUR HISTORYHastings has been designing and manufacturing piston rings since 1923.Hastings Manufacturing was born into the automotive industry in 1915. By 1923our focus became dedicated to the design and manufacture of piston rings. In1956 we invented the Flex-Vent® oil control ring, which quickly became theinternational standard for most engine applications, and made famous in theaftermarket by our legendary “Tough Guy” character. In the 1980’s the Flex-Vent oilcontrol ring became the choice of OEM’s worldwide and is still specified in today’sengines. Not to be satisfied with dominating oil ring technology, Hastings offers thebroadest selection of steel and cast iron compression rings in themarketplace. Today, with plans in placeto improve upon our products andmanufacturing efficiencies, thefuture looks even brighter forHastings and our customers.The Hastings “Tough Guy” is tough on oilpumping and gentle on cylinder walls.Hastings is proud of its valuedreputation in the industry.800-776-1088 • www.hastingsmfg.com3

OUR STRENGTHSQUALITY REGISTRATIONSWe are relentless in the pursuit of Quality, Excellence, andContinuous Improvement (QECI). As a primary innovator ofpiston ring design and technology, we offer the quality andreassurance inherent with having our own on-site foundry,specialized manufacturing processes, and hard-earnedTS-16949 and IS0-14001 registrations. Hastings is alsoQMS certified by Intertek.APPLICATION COVERAGEOur product line consists ofover 16,000 part numbers, orover 25,000 unique piston ringsets in bore sizes from 1.75"to over 10". Material optionsinclude cast iron, hi-tensilenodular iron, 9254/1070 steels,and 201/301 stainless steels.Coatings can be applied inplasma-moly, chrome, nitride,and Manganese phosphate.Piston ring profiles includerectangular, barrel face,torsional, full/half keystone,and others.COST, QUALITY AND DELIVERYHastings Manufacturing QECI goals include Our exclusive CNC machiningbeing the lowest-delivered-cost-supplier of processes, used for the manufacture ofquality products and services, delivered on product and tooling, significantly reducetime, every time—in full responsiveness to development and revision lead times.the demands of our customers and prospects. Hastings believes it can only provide theThis is achieved in part by utilizing a combination highest quality products to a value-consciousof proprietary and industry-standard equipment. customer base by maintaining an ongoingcommitment to the achievement of Quality,Excellence and ContinuousImprovement, atall levels of ourorganization andin everythingwe do.INNOVATIONHastings invented and patented the Flex-Vent® oil control ring. Wealso patented and manufacture the Hyper-Vent® oil controlring. Hyper-Vent, only available from Hastings, isspecified in OEM engines for better oil economy,with reduced friction and increased flexibility.We employ in-house, high-speed oil ringfabrication machines and chrome platingfacilities, which enable us to optimizefor any product specifications.800-776-1088 • www.hastingsmfg.com 5

INDUSTRY STANDARD EQUIPMENTOur products are manufactured using Hastings-developedproprietary equipment in concert with specialty equipmentacquired from industry leaders in the fabrication ofpiston rings, such as:• Sundstrand splitters• Besley and Nissei grinders• SIM, Dimaco, and B&K cam turn, bore andgap milling machines• SIM and Dimaco size grind machines800-776-1088 • www.hastingsmfg.com7

PROCESS STRENGTHSGAUGE DESIGN CNC MACHINING, DESIGN AND PROGRAMMING NOMOGRAM RING DESIGNProprietary Hastings-designed processesinclude parametric CNC programming formanufacturing products and tooling though themodification of variable inputs. This includesintegrated design systems that use productdimensional data to automatically designtooling, track revisions, and create numericalcode for manufacturing. Standard CNCmachines have also been adapted by Hastingsto perform specialized tasks using input fromour external gauging systems.Hastings engineering through nomogramscan optimize ring design and minimizedesign and development time.Hastings utilizes industry-standardmeasurement systems. For specializedapplications, our engineers have designedproprietary measurement equipment,including:• Tangential tension tester• Expander tooling gauges• Digital gap gauging• Digital multi-point width testingHastings gauging systems areTS-16949 compliant.VISION INSPECTIONSYSTEMSWhether through SPC, mistake proofing,or automated in-process inspection,we utilize the latest vision and lasertechnology to insure our products meetcustomer specifications.• In process laser measurement forproduct characteristics, orientation,and defects• In process laser measurement fortooling compensation• In process vision system for toolinggeometry verification• Real-time SPC collection8800-776-1088 • www.hastingsmfg.com

QUALITY SYSTEMSDESIGN AND TESTING VERIFICATIONAs a TS-16949 registered company since 2002, Hastings Manufacturing has integrated qualityassurance systems into all its processes. This includes:• Metrology labs• Process capability studies• Networked SPC data entry or SPCcharting for significant characteristics• Mistake proofing• Ring failure analysis labIn an effort to predict real-world reliability, Hastings is committed to design and testing verification,simulation, and analysis. This includes 3-D solid modeling to ensure accurate and timely productand tooling design. Hastings has partnered with industry-leading firms to offer advancedengine testing and simulation.Here are some of the procedures we employ:• 3-D solid modeling and simulation software formachine and product design• Proprietary software developed by Hastings topredict compatibility of Flex-Vent three-piece oilrings with the piston and automatic loading machines• Proprietary software to aid in the design ofthree-piece oil rings, including spring rates,material, and tooling• Dimensional and profile measurement• Angular orientation measurement• Digitized imaging• Advanced capabilities studies800-776-1088 • www.hastingsmfg.com 9

OIL CONTROL RINGSWhen it comes to oil control rings, Hastings is the innovator.We invented the multi-piece oil ring followed up by theFlex-Vent® expander, the design standard by which allother oil rings are compared.10800-776-1088 • www.hastingsmfg.com

OIL CONTROL RING TYPESOil rings distribute and regulate oil within the cylinder wall and help scrape it back into the crankcase. This is necessary to keep the cylinder walllubricated with the cooler replacement oil, thereby aiding the heat transfer and lowering the friction between the piston and its cylinder.Hastings Manufacturing offers three-piece Flex-Vent oil rings and one-piece and two-piece cast iron oil rings.Three-PieceFlex VentOil RingTwo-PieceCast IronOil RingWith CoilSpringTwo-PieceCast IronOil RingWith InnerSpringOne-PieceCast IronOil RingWe can collaborate with our customer to design a unique product for specialized applications.DESIGNS AND SIZES FOR THREE-PIECE OIL CONTROL RINGSThree-piece oil control rings are available in multiple sizes and configurations in diameters from 1.338" to 10.687".800-776-1088 • www.hastingsmfg.com11

OIL CONTROL RINGSTHREE-PIECE FLEX-VENT ® OIL RINGSOIL CONTROL RAILSOIL CONTROL EXPANDERSHastings invented the three-piece oil control ring with patented Flex-Vent® technology.Flex-Vent has become an industry standard and is offered in a wide range of designs and sizes.We also designed and patented the Hyper-Vent® oil control ring.1070 Steel• Tough, wear resistant, high carbonspring steel• Resists fatigue and permanent set• Used to manufacture oil ring rails201 and 301 Stainless• Chromium-nickel stainless steels capableof attaining high tensile strengths throughcold working• Corrosion resistant• Can be nitrided• Used to manufacture Flex-Vent expandersThe Flex-Vent expander oil ring isenergized by two steel rails, which receiveuniform pressure from the expander toassure positive oil control. The three-piecedesign allows rails to be manufacturedwith a small cross-sectional area for betterconformability to the bores of today’slow-tension, low-friction engines. Therails thin wall contact also allows for quickbreak-in time. Hastings rails are normallychrome plated to extend engine life.The Flex-Vent expander regulates thetension of the oil control ring assembly.Other advantages include:• Both straight and angled tabs forbetter side sealing• Step pad for increased expander stiffness• Designed to conform to cylinder wall withuniform pressureFor new application solutions, ourparametric design for product and toolingenables rapid prototyping.12800-776-1088 • www.hastingsmfg.com

COMPRESSION RINGSHastings’ compression rings are the product of nearly 100 years of design,process and manufacturing output, including an in-house foundry andfinely tuned systems for testing, simulation, and production.14800-776-1088 • www.hastingsmfg.com

SECOND COMPRESSION RINGSSecond compression rings scrape oil and prevent it from reaching the combustion chamber. They also provide a second seal fortrapping combustion gases and aid in heat transfer.DESIGN STRENGTHS & APPLICATIONSThere are several options for second ring profiles, each providing specific advantages depending on the particular application.Reverse Torsional Taper Face Profile• Reverse twist along with a tapered ringface creates bottom edge scraping• Reverse twist promotes side sealing thatprevents oil from being forced under andbehind the ring, resulting in betteroil economy• Very common second ring profile in moderngas engines• Multiple scraper face geometries withalternative iron choices at various tensionsTorsional Profile• Twist in ring creates low edge O.D. contact,scraping oil down the cylinder wall• Sharp edge contact helps speed break-inWiper Profile• An additional groove machined into the bottomedge of the ring face provides both twist and anoil accumulator for improved oil scrapingand oil economy volumeReverseTorsionalTaper FaceTorsionalWiperWe can collaborate with our customer todesign a unique product for specializedapplications.800-776-1088 • www.hastingsmfg.com15

TOP COMPRESSION RINGSTop compression rings trap combustion gases and increase the combustion pressureand efficiency. They also play a major role in the heat transfer process betweenthe piston and cylinder wall.STEEL TOP COMPRESSION RINGSAISI 9254 Steel Top Compression Rings:• Silicon Manganese spring steel used in the most demanding high-compression,high-stress, and high-temperature ring applications• Nearly twice as strong as high-tensile nodular iron• Allows for thinner, lighter ring designs that maintain better sealing at high RPM's by stayingseated against the groove bottom• Reduced side wear and extended lifeCAST IRON TOP COMPRESSION RINGSCast iron and high-tensile nodular iron rings also have many applications and advantages,including both economic and performance:Regular Cast Iron Rings• Best thermal conductivity of availablering materials to transfer combustionheat to the cylinder walls• Durable gray iron due to Hastings’graphite structure and distinctive alloys• Lubricating graphite flakes allow ringsto function without expensive coatings• Widespread use for second groove ringmaterial and top groove rings in lessdemanding applicationsHi-Tensile Nodular Iron Rings• Stronger and more ductile than gray iron• Can withstand higher operating temperaturesthan gray iron• Will not break upon installation or underextreme stress• Top groove ring material used in manylate-model and high-performance orturbo-charged applications• Alternative to 9254 steel rings16800-776-1088 • www.hastingsmfg.com

DESIGN STRENGTHS AND APPLICATIONSCOATINGSHastings top compression rings feature multiple profiles with specific advantages and applications:Barrel Face• Increased sealing• Reduces time for rings to seat• Available with either moly, chrome,or triple chrome coatings• Available in iron and steel• Most common top ring profilein gas enginesTorsional• Increased side sealing• Better oil control• May have barrel or straight face• Available with moly or chrome coating• Available in cast iron or steelBarrel FaceTorsionalFull/Half Keystone• Primarily used in diesel applications• Tapered cross section prevents carbonbuild up and ring sticking, and createsadditional surface area for side load bearing• Available in torsional designs for betterside sealing and oil control• Usually chrome plated for extendedservice lifeRectangular• Lowest cost profile• Used primarily in two-stroke engines,pumps and compressorsFull/Half KeystoneRectangularHastings offers the broadest selection of moly, chrome, and cast iron compression rings in theindustry, assuring the proper ring pack for every application.Manganese Phosphate• Prevents corrosion and eliminates gallingof rings during startup and break-in• Used on iron or steel compression ringsChrome• Hard, wear resistant, and low friction• Prevents bore scuffing when usinghigh-tensile iron and steel rings• Can be used to coat the face and sidesof rings (triple chrome)• Preferred over moly in dusty environmentswhere the porosity of moly can trapcontaminates• Primarily for use on cast iron boresPlasma Spray Molybdenum• Hard and wear resistant• Prevents bore scuffing when usinghigh-tensile iron and steel compression rings• Porosity traps lubricating oil• Can be used with majority of bore materialsNitride• Hard, wear resistant, and low friction• Hardens all outer surfaces of the ringfor increased wear resistance• More environmentally friendly thanchrome plating• Can be used to harden Flex-Vent expandersWe can collaborate with our customer to design a unique product for specialized applications.800-776-1088 • www.hastingsmfg.com17

FOUNDRY OPERATIONSFOUNDRYSANDMOLDSHastings uses the highest quality,ISO-registered resin sand suppliers. Highquality sand results in less imperfectionsin the mold making process and lessmachining of the metal casting.After years of operating our own on-sitefoundry with shell-molding process, wehave perfected casting to maintain highvolume flow rates, minimize costs, andprovide superior quality castings.Burning resin during the pour creates ananti-oxidizing atmosphere, which slows thesurface-cooling rate, promoting a ferritic-skinwith excellent machining and fine-finishcharacteristics. This results in cast ironPATTERN DESIGNAND BUILDINGHastings in-house CNC pattern-makingmachines allow for a wide range of patternsizes, and provide the necessary accuracyin the shell-molding process.CASTINGSOur castings are designed for tighterdimensional tolerances, better surfacefinish, and smaller draft angles with nearnet shape.The custom shape and design of our moldpatterns allow flexibility within the moldingprocess to run multiple diameter patternsfrom small to large runs. The controlledand integrated process ensuresconsistent molds.QUALITY CONTROLwith properties that are beneficial to bothinstallation and wear.An in-house lab with dedicated carbon,spectroscopic, and microstructure analysisequipment, used in conjunction with SPC,sets rigid standards in controlling the qualityof our castings.18800-776-1088 • www.hastingsmfg.com

DESIGN A RING PACKHastings can recommend one of over 16,000 existing ring designs we currently manufacture, or we cancollaborate with the customer to design a unique product for the application. Exclusive parametric product andtooling design software, as well as broad offerings in standard ring profiles, materials, coatings, and availabletooling enable Hastings to manufacture new products quickly and cost effectively.Hastings Manufacturing is dedicated to providing best-in-class design and manufacturing solutions thatresult in the industry's best value to our customers.OIL SECOND TOPWe can collaborate with our customer to design a unique product for specialized applications.800-776-1088 • www.hastingsmfg.com 19