Advancements in engine design, although seemingly simple compared to developing an all-new powertrain system like the Chevrolet Volt's high-tech setup, can still provide a boost in efficiency and a reduction of overall emissions. For example, slashing piston mass by a mere seven percent and reducing its friction can diminish fuel consumption by one percent. If the reduced consumption sounds minimal, that's okay. It really is. But when the piston in question is Federal Mogul's next-gen Magnum Monosteel, a unit designed for heavy-duty diesel-burning big rigs, any efficiency improvement is most welcome.

So, what sets the Magnum Monosteel design apart from more conventional diesel pistons? Well, Federal-Mogul describes the key differences like this:
The key differentiator for the Magnum, however, is its unique "double-band" piston skirt design-a first for modern diesel pistons. The double-band skirt helps to reduce frictional drag and reduces the overall piston skirt area by 40 percent, making this innovative design feature the primary contributor to the Magnum's overall friction and mass reduction. Extensive engine testing has shown piston friction reduction of up to 17 percent, compared to conventional steel piston designs.
Yeah, it's just a piston. But this one's high-tech design reduces emissions, improves fuel economy and offers improved durability. It's not sexy, but it works for us.

[Source: Federal Mogul]

PRESS RELEASE

Federal-Mogul's New Magnum Monosteel™ Piston Offers Improved Fuel Economy and Reduced Emissions for Heavy-Duty Vehicles


SOUTHFIELD, Mich., Oct. 14 /PRNewswire/ --Since its introduction in 2003, Federal-Mogul Corporation's (Nasdaq: FDML) Monosteel® piston has become an industry standard for heavy-duty diesel vehicle applications with more than 3.5 million pistons produced to date. Federal-Mogul today announced that it has developed the next generation of the Monosteel piston, called Magnum Monosteel™. The new design reduces piston mass by up to seven percent and includes design features that reduce friction for improved fuel economy and lower emissions.

The Magnum Monosteel piston is in development testing with major global commercial vehicle and engine manufacturers in North America and Europe. Like the original Monosteel piston, the Magnum addresses the increasing thermal, mechanical, abrasion and corrosion challenges placed on heavy-duty diesel engines resulting from stringent emissions regulations. The original Monosteel and new Magnum Monosteel have patented dual friction-welded construction, which enables large cooling galleries for superior high temperature resistance and strength to withstand the highest cylinder pressures found in modern commercial vehicle engines.

The key differentiator for the Magnum, however, is its unique "double-band" piston skirt design-a first for modern diesel pistons. The double-band skirt helps to reduce frictional drag and reduces the overall piston skirt area by 40 percent, making this innovative design feature the primary contributor to the Magnum's overall friction and mass reduction. Extensive engine testing has shown piston friction reduction of up to 17 percent, compared to conventional steel piston designs.

The Magnum's double-band skirt also enables better hydrodynamic lubrication as compared to conventional piston skirt designs. The improved lubrication allows for greater piston stability as well as optimal ring pack performance and durability. Federal-Mogul developed the Magnum piston at its Powertrain Energy technical center in Plymouth, Mich. -- one of the company's 18 globally networked technical centers.

"With the Magnum piston, Federal-Mogul is again bringing a significant piston architecture innovation to the heavy-duty market through an enhancement to our proven Monosteel design," said Rainer Jueckstock, Federal-Mogul senior vice president of Powertrain Energy.

"Like our industry-leading Monosteel piston, the Magnum with its fuel economy benefits is another game-changing technology that provides heavy-duty customers with a more effective solution to the emissions challenges they face," added Jueckstock. "In addition to on-highway applications, the Magnum is well suited for industrial and marine applications as well. This new leading technology will strongly contribute to our strategy for sustainable global profitable growth."

About Federal-Mogul

Federal-Mogul Corporation is a leading global supplier of powertrain and safety technologies, serving the world's foremost original equipment manufacturers of automotive, light commercial, heavy-duty, agricultural, marine, rail, off-road and industrial vehicles, as well as the worldwide aftermarket. The company's leading technology and innovation, lean manufacturing expertise, as well as marketing and distribution deliver world-class products, brands and services with quality excellence at a competitive cost. Federal-Mogul is focused on its sustainable global profitable growth strategy, creating value and satisfaction for its customers, shareholders and employees. Federal-Mogul was founded in Detroit in 1899. The company is headquartered in Southfield, Michigan, and employs nearly 43,000 people in 34 countries. Visit the company's Web site at www.federalmogul.com.

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