reconditioning of aluminium engines

[shogun]

Chapter 1
1.1 Reasons for using aluminium cylinder blocks
1.2 Known brands of aluminium alloys for cylinder blocks
1.3 Vehicles/engines with aluminium cylinder blocks
1.4 Design details
1.5 Composite materials for cylinder liners. Aluminium/cast iron
1.6 Use of Cr-coated piston rings
1.7 KS cylinder liners for Alusil engines

Chapter 2
Reconditioning an Alusil®cylinder block

2.1 Preparatory machining of the cylinder block
2.2 Installation of the Alusil cylinder liner
2.2.1 Installation with dry ice
2.2.2 Installation with liquid nitrogen
2.2.3 Preheating of the cylinder block
2.2.4 Fitting the cylinder liner
2.3 Planing of the cylinder block
2.4 Prehoning, finish honing, polishing
2.5 Silicon lapping
2.6 Tables

Chapter 3: Reconditioning a Lokasil cylinder block based on the example of the
Porsche Boxster engine

Chapter 4: Reconditioning the threads for the cylinder head bolts

Vehicles/engines with aluminium cylinder blocks
GALNIKAL / NIKASIL
BMW
2.0 Litre 6 cylinders
2.5 Litre 6 cylinders M52
2.8 Litre 6 cylinders M52
3.0 Litre V8
4.0 Litre V8
Motorbike 100 K
JAGUAR
V 8

ALUSIL / SILUMAL
MERCEDES-BENZ
3.8 Litre before 8.81
3.8 Litre after 8.81
4.2 Litre
5.0 / 5.6 Litre
6.0 Litre
PORSCHE
928
928 S
944
BMW
750 i
3.5 Litre V8
4.4 Litre V8
AUDI
V8 4.2 Litre
V6 2.8 Litre

LOKASIL
PORSCHE
Boxster

Known brands of aluminium alloys for cylinder blocks
KOLBENSCHMIDT... MAHLE
Alusil.................. Silumal
Galnikal............... Nikasil
Chrome cylinder.... Cromal
Lokasil (KS patent)

Design details
Alusil:
• Alusil base material is expensive and difficult to machine due to the high silicon content
• Boring the cylinder block is possible
• Oversized pistons are available
• Pistons in Alusil blocks are coated with iron and tin

Galnikal:
• Galnikal base material is cheaper than Alusil and easier to machine due to its substantially lower silicon content
• The cylinder bore is nickel coated
• Boring the cylinder block is not possible because of the nickel coat !
• Oversized pistons are not available

Chromium cylinders:
• As Galnikal
• but: the cylinder bore is chromium coated
Lokasil / KS patent:
• Lokasil base material costs less than Alusil and is easier to process.
• Preforms, which are special prefabricated liners from Lokasil with a high silicon content of 20 - 27 %, are cast into the cylinder bore
• Oversized pistons are available
• Boring of the cylinder block is possible

Includes also info on BMW M70 12 Cylinder

http://www.w124performance.com/docs/general/aluminum_engine_reconditioning.pdf

[genphreak]

Some practical alumagic in there. A friend has a nikasil block with a melted piston yesterday. The piston lost 10% of its mass at least, the rings had no material around parts of them. Seemingly both were toast, but he showed me how the molten alloy from the piston can be removed from the walls using acid, leaving the bore clean and perfectly serviceable. Wow!

[Tiger]

That's pretty cool... where is he located? Got a spare V8 Nikasil... maybe to rebuild... still debating.

[genphreak]

No I doubt it, I think the leak-down symptoms in US Nikasil blocks comes about as the sulfur destroys the Nikasil coating over a period of prolonged service, the block can be saved bu probably would require a bore and the installation of 8 steel bore liners. Sorry Tiger, I was talking about a Suzuki motorbike engine mate...