ALUSIL ® -Cylinder Blocks Porsche V6/V8 - KSPG AG

nearly 100 %, depending on the heat treatment condition. As
a result, commercial bolt heads hardly lead to an appreciable
setting of the aluminium even if the bolt was tightened up to
the tensile yield point.
7. Description of the casting die and development/adjustment
of the casting process
The synergy effect envisioned by Audi when changing from
the V6 to the V10 cylinder blocks was fully achieved in terms
of casting tool design, conceptual design of the machining
equipment and test devices and, in particular, the development
and adjustment of the casting process. Thanks to sustainable
exploitation of all possibilities of virtual product and
Fig. 11: Solidification simulation with the example of the V6 cylinder block
Top: Residual solidification zone (risk of blowholes) in the gearbox flange area without active cooling measures
Bottom: Optimized condition; avoidance of blowholes (no residual solidification zones) through selective active cooling measures
10
Critical residual solidification zone
process development based on a consistent CAD, CAE, CAM
line (Figs. 11, 12), the targeted effective optimisation of the
cylinder blocks was accomplished.
8. Summary, conclusion and outlook
For its state-of-the-art high-performance gasoline engines of
V design, Audi stakes on the combination of ALUSIL ® lowpressure
die casting and mechanical silicon grain exposure.
In the present situation, this combination offers optimum
conditions for the engine functions, production and process
reliability as well as quality. Hence there are quite a number
of factors speaking in favor of ALUSIL ® to be rated as one of
the best materials available today for high-performance gas-