I understand that CGI can be used for material substitutions or for completely new engine developments. Which types of applications are most common?

Shareholder, name withheld

Compacted Graphite Iron can be applied for the following three types of projects:

1. Material Substitution: to use CGI with the existing design to allow for power-up or to eliminate premature failures.

2. Product Re-design: to use CGI to reduce internal wall thickness and thus achieve weight reduction. These applications require that the outer dimensions of the casting remain unchanged to ensure backward compatibility with other components.

3. New design: to use CGI to design a component from a ’clean sheet of paper’. These components can be fully optimised for CGI with no design or manufacturing constraints.

SinterCast is currently supporting pre-production programs in each of the three categories. Material Substitution (Category 1) is primarily for heavily-loaded applications, or for products where the loading has increased since the original product launch. The Iveco 12 litre V6 SinterCast-CGI cylinder head used in the Italian Coast Guard application is a classical example of a Category 1 product. The Ford-PSA 2.7 litreV6 diesel engine is a classical example of a Category 3 ’clean-sheet’ product. The primary advantage of Category 3 products is that they also have purpose-built manufacturing facilities.

SinterCast will have series production in each category. However, as time passes, the Category 3 applications will predominate.