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MAHLE Develops New Generation of Thermally Insulating Piston Coatings

A new generation of MAHLE piston coatings is being developed with the purpose of increasing efficiency and minimizing emissions. These coatings are intended to guide and reduce the heat entering the pistons.

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A new generation of MAHLE piston coatings is being developed with the purpose of increasing efficiency and minimizing emissions. These coatings are intended to guide and reduce the heat entering the pistons. This initially reduces the demand for piston cooling, and the increased exhaust gas temperature allows a higher quantity of energy to be extracted by waste heat recovery (WHR) systems. At the same time, the higher exhaust gas temperature permits faster heating of the exhaust gas after-treatment system following the cold start. The resulting decrease in NOx emissions makes it easier to comply with current and future legislation.

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MAHLE achieves additional positive effects by optimizing the piston galleries—for instance, the MonoLite piston with its kidney-shaped cross section. This allows a temperature reduction of up to 20 kelvin without any negative impact on the aging process of the oil used. The combination of reduced oil flow and a small compression height helps to minimize friction and fuel consumption.

In the commercial vehicle sector, the diesel engine will remain the dominant drive source for the foreseeable future, despite increasing diversification of the powertrain. This makes it even more important to continuously develop the diesel engine in order to reduce emissions and operating costs. Thanks to its holistic systems competence, MAHLE is able to tap new savings potential where no further improvement is possible at component level.

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