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CONCEPT CARS: As in past years, the IAA in Frankfurt was a platform for future design studies, with a special focus on space this time. Some of the futuristic concepts gave visitors the impression of remote galaxies. Available space was used much more effectively in many of the cars. Due to the disappearance of the B-pillar both the optics and access were much improved in many concepts, with wing doors opening upwards in some cases. Alternative drives were another important trend, hybrid technologies being one of the main areas of interest. These drive an electrical engine with much lower fuel consumption levels. Other manufacturers concentrated on hydrogen or gas as alternative fuels. These new drive systems do not automatically mean reduced power as demonstrated by Ford’s Iosis study with more than 300 h.p. from an electrical engine. The Concept Cars pictured on these two pages give an impression of what might be driving on our roads in years to come (shown clockwise starting top left): Suzuki Concept X, Peugeot 20cup, Mazda Sassou, Maybach Exelero (top speed 351.45 km/h), Mitsubishi Concept Sportback, Toyota Endo, Peugeot Moovie, Citroën Sport Lounge, Jaguar R Coupe, Mini Concept Frankfurt, Ford Iosis and DaimlerChrysler Bionic. Newsline 10 Photos (12): Ford (3), Citroën, DaimlerChrysler (2), Mitsubishi, Toyota, Peugeot (2), BMW Group und Suzuki.
Newsline Kolbenschmidt Pierburg in the new Allroader from the German car manufacturer Engine block and intake manifold for Audi Q7 Ingolstadt/Düsseldorf. The booming market for Sport Utility Vehicles (SUVs) demands a high seat position, good overview, sturdy appearance and representative dimensions, all of which the Audi Allroad Quattro can only fulfill to a limited degree although it still offers a good mix between on and off road capabilities. Audi has now decided to venture onto the highly competitive SUV market with a new model. Series-production of the Audi Q7 that is based on a study of the Pikes Peak Quattro will probably be launched in early 2006. It will initially be available in two engine variants: a diesel V6-TDI engine and the 4.2 liter V8 FSI gasoline direct injection engine. The engine block for the V8 drive with bedplate concept will be supplied by KS Aluminium Technologie AG (ATAG). The engine block of the V8 engine will be cast from a hypereutectic aluminum-silicon alloy known under its tradename ALUSIL®, a material offering numerous advantages. The monolithic, linerless concept allows an extremely compact design with minimal bridge width of only 5.5 mm between the cylinders, allowing low weight and high integration. This concept is also distinguished by the optimum thermal conduction properties which permit high specific engine performance characteristics. The non-armored cylinder bore surfaces are extremely resistant to seizure, and the pistons and piston rings run on hard silicon crystals. The low pressure die-cast engine block guarantees a uniform deposit of silicon crystals in the cylinder bore surface combined with minimal porosity. Besides the controlled, low-turbulence mold filling process, the directional solidification is also noteworthy. The casting process allows the introduction of sand cores, so that structurally stiff engine blocks are manufactured in a closed deck design as for the V8 engine. Another advantage derived from the low pressure die-casting process is the unlimited heat treatment of the casting, permitting not only greater hardness and higher strength, but also volume stabilization. The mechanical “uncovering” of silicon grains is just one of the outstanding features of the V8 FSI engine bock. The process employed by Audi is very similar to the ATAG-patented Siplamec honing method. This process consists of three phases: pre-honing, basic honing and finish-honing, the third step being determining. The desired surface structure is obtained by using elastic honing stones, which – due to the resilience of the cutting grains – remove more Al-matrix than Si-grain at the hard cutting grains. The Si-grains protrude slightly from the Al-matrix contrary to chemical process with rounded edges. This reduces the risk of splinters and also decreases piston ring wear susceptibility. 11 Yet not just the technology as such but also the time needed to develop the engine block for the new Audi Allroad V8 engine has set new standards. The simultaneous engineering process adopted by Audi, ATAG and the tool manufacturer made it possible to reduce the development time very considerably, backed by the benefits of virtual product development. A further technical highlight of the Audi Q7 is the new 2-length magnesium intake manifold from Pierburg GmbH. The longitudinal actuating flaps and tumble plates of this intake manifold are driven by the EAM-b electrical adjusters developed by Pierburg. Vacuum-pressure actuators are therefore not needed so that the intake manifold can switch independent of the vacuum supply. To achieve optimum torque values over a larger speed range, the intake manifold installed in Kolbenschmidt supplies the engine block, Pierburg the advanced 2-length intake manifold: the new Audi Q7 Allroader. the Audi Q7 has two lengths – irrespective of the engine speed: a short intake length assures good performance in the upper speed range and a longer intake distance permits optimum torque behavior at medium speeds. One general difficulty encountered in connection with optimum intake manifold functions is the internal sealing of the unit. To achieve high torques, Pierburg has given the manifold maximum internal sealing properties. This has been done in three different ways: firstly, the longitudinal actuating flaps attached by hot-riveting are sealed with elastomerics, secondly the welded tumble plates are pressed-in thus ensuring good tightness and thirdly, the channel-shaped magnesium parts are package-bolted. Photos (2): Audi
Page 1 and 2: Appealing The Kolbenschmidt Pierbur
Page 3 and 4: Newsline Appealing IAA exhibits wit
Page 5 and 6: Photos (2): Airbus Industrie telero
Page 7 and 8: Rheinmetall in Düsseldorf and has
Page 9: Newsline WELL POISED: The Kolbensch
Page 13 and 14: (Continued from page 12) tank crew
Page 15 and 16: Bremen. Interoperability is crucial
Page 17 and 18: The new EOD Cutlass, representing t

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