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Photo: Audi AG Engine blocks for new Audi A6 Ingolstadt/Neckarsulm. KS Aluminium-Technologie AG (ATAG) is the sole supplier of the new Audi A6 gasoline engine block available in 2.4- and 3.2-liter options. The 2.4-liter version with multipoint injection develops 130 kW and complies with EU4, as does the 3.2liter FSI V6 with 166 kW, a 169.5-kg engine with a maximum torque of 330 Nm. On the new V6 engine block Audi wanted Alusil, a lowpressure die-cast hypereutectic aluminum-silicon alloy. The new engine block would dispense with the gray-cast iron sleeves inserted into the cylinder bores of its predecessor.In the case of this alloy, the silicon crystals exposed while the engine block is being machined, form an ideal, wear-resistant mating surface for the pistons. No cylinder sleeves—this also means a more compact engine block design as such. Other advantages of this all-aluminum block are its improved heat conductivity compared with gray cast iron and reduced cylinder warpage. Superior heat conductivity, in turn, lessens the thermal load on the engine and allows greater volumetric efficiency. Developed inside only 3 years as a joint effort between Audi and KS ATAG, the V6 gasoline engine block project absorbed heavy double-digit million euro expenditures on the part of the Neckarsulm-based specialist. Items on the bill included casting cells, machining centers and peripherals such as sawing and decoring stations, and leakage testers. Newsline First RLS system delivered – further orders to come Büffel 3 for Swiss Army Thun/Kiel. Reinforcement for the Swiss armored forces: The Swiss Army recently took delivery of the first of 25 armored recovery vehicles (ARV) approved under the Armament Program 2001. The latest version of the ARV 3 combines advanced recovery technologies with the proven assemblies of the Leopard 2 main battle tank, meeting the more stringent requirements of modern-day forces. Tailored specifically to Swiss specifications, the Büffel ARV version which has now been handed over is d i s t i n - guished by enhanced performance characteristics and an improved functionality. These systemadvantages are ensured by a fourth integrated crew member, an extended working range, a modified support and clearance system, improved handling characteristics, a better view, greater protection and more stowage space. Important parts for production of the recovery vehicle in Germany – such as the crane jib, and the support and clear- Photo: Thomas Klink 8 ance system – are being supplied by the Swiss industry under a co-production agreement. In addition, drive assemblies and further running gear components are being taken from Swiss Army reserve stocks from armasuisse (Bern). As the procurement and technology center of the Federal Department of Defence, Civil Protection and Sports DDPS, armasuisse is in charge of the development, evaluation, procurement, and disposal of equipment and infrastructure for the armed forces and other customers. The new ARV 3 is the first vehicle of the recovery vehicle generation to have a fourth integrated crew member. The entire equipment and stowage has been adapted to Swiss conditions. The second ARV will be converted to a diagnostic trainer which can be modified back into the normal vehicle configuration relatively quickly. Other countries to have ordered the latest armored recovery vehicle from Rheinmetall Landsysteme GmbH are Sweden and Greece. The first of 25 armored recovery vehicles 3 approved under the Armament Program 2001 was recently handed over to the Swiss Army in Thun. Photo: Ulli Ullmann ATAG wins Porsche Supplier Award Leipzig/Stuttgart. Important distinction: KS Aluminium-Technologie AG (ATAG) recently won the Porsche Supplier Award 2003 at the Porsche Supplier Day held in Leipzig. The automaker from Stuttgart awarded the prize to its ten best suppliers. Joining the illustrious group of top suppliers for the first time, Neckarsulm-based specialist was awarded the distinction thanks to the excellent standard of its Porsche engine blocks and the production launch of the eight-cylinder engine block for the Porsche Cayenne (see picture on right).
Photo: Katja Kletzke Newsline Calibration of test equipment – another key service with which the EZU can excel on civil markets. EZU test center has a lot to offer Serving the military and civil sector Unterlüß. Tucked away in the woodland of the Lüneburg Heath in Lower Saxony, the EZU (Erprobungszentrum Unterlüß) in Unterlüß has a lot to offer: as a service center for the restructured Rheinmetall Waffe Munition GmbH and numerous customers from various branches of the industry, it has both the space and the capabilities required to test large caliber weapon systems and ammunitions. As one of the very few privately owned military proving grounds in the world, the EZU also has a lot to offer for non-military clients. Many of the measurement and test techniques applied at the EZU are unrivaled in the world. Newsline recently visited the 50 km 2 heathland and test facilities to find out more about the EZU. boiling hot or pouring with rain: “Our working day in Unterlüß starts at sunrise and ends when the sun sets, and a lot of our time is spent outdoors,” says Karsten Lunkeit, the engineer in charge of the EZU and the Quality Management department. For the 110-strong staff this mainly involves: assembling, disassembling, testing, measuring and improving. In the heart of the heathland in Lower Saxony, armored and other large vehicles are “heated” under tropical conditions in the temperature testing facility, ticket machines have to function properly even under arctic conditions. Unique systems are used to photograph tank ammunition as it leaves the muzzle only to burst in a huge catch box shortly afterwards, and windows with security glass have to withstand explosions. Many a gas tank for cars has been detonated in Unterlüß to test traffic safety. As a service center not only for the weapons and ammunitions sector, the EZU is undergoing a process of change to diversify its activities, especially in times of changing global conditions. “We found that our proving ground is extremely interesting and well suited for tests in connection with anti-terror actions like, for example, the protection of buildings, and we are currently holding talks with interested customers,” says Ellen Dudek, EZU sales manager. On the rare occasions when there is actually no firing on the range, staff busy themselves with tidying up the proving ground and servicing the test equipment. No firing also means that the employees of the EZU can move around the site without restriction. Of course, traffic continues on the EZU site A team with a clear strategic goal: sales manager Ellen Dudek and EZU boss Karsten Lunkeit are increasingly diversifying the activities of the EZU in Unterlüß (which has a wealth of experience in testing and qualifying military products) into the non-military sector. EZU specialists visit their customers when requested to do so. 9 even during firing sessions, although traffic is strictly controlled at such times – even on the national road which crosses the site. Naturally, not the entire area is prohibited: depending on the customer’s requirements and the type of tests being performed, only certain areas are used – i.e. planning is completely flexible to suit the respective needs. After all, customized solutions are part of the EZU’s program. For instance, the temperature test facility which has been in operation for 30 years now is one of the most modern of its kind. The two chambers with a total capacity of just under 1,000 m 2 have served the classic requirements imposed on military vehicles since the very beginnings: will the engine of an armored vehicle start at –40°C, how hot does it get at outside temperatures of +40°C and how does the temperature affect the weapon system? The (Continued on page 10) Photo/Composing: Katja Kletzke
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