The use of Selected Lean Management Tools for Analyzing Defects in Pistons for Internal Combustion Engines

Author:

Piątkowski J.1ORCID,Łent-Trepczyńska M,Krępa A.2,Ferdyn M.3

Affiliation:

1. Faculty of Materials Engineering, Silesian University of Technology, Poland

2. Federal-Mogul Gorzyce, Poland

3. Magna Casting Kędzierzyn-Koźle, Poland

Abstract

The article presents the most significant material defects found in pistons for internal combustion engines, along with a graphical method of categorization using a Pareto-Lorenz chart. For the top three defects (constituting approximately 80% of all issues), a slightly different Ishikawa chart was employed to identify the causes behind their occurrence. Remedial actions were proposed, to be implemented primarily within the interoperative quality control of piston casting. It was concluded that it is crucial to prevent the excessive iron content in the alloy used for alfin inserts (AS9 alloy), particularly for cast iron ring carriers. The research was conducted in collaboration with Federal-Mogul company in Gorzyce (F-MG), one of the largest piston foundries in Poland.

Publisher

Polish Academy of Sciences Chancellery

Reference3 articles.

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2. Czerepak, M. (2020). The crystallization of AlSi9 alloy designed for the alfin processing of ring supports in the engine pistons. Archives of Foundry Engineering. 20(2), 65-70. DOI:10.24425/afe.2020.131304. [14] Piątkowski, J. &

3. Krępa, A. (2023). Casting pistons for combustion engines from aluminum alloys over 50 years of experience Federal-Mogul Gorzyce. Foundry Journal. 73(3/4), 84-85. (in Polish). [15] Piątkowski J., Czerepak M. (2023). Improving the quality of bimetalic connection between the ring insert and the engine piston. In METAL 2023: 32nd International Conference on Metallurgy and Materials, 17-19 May 2023 (40-41), Brno, Czech Republic. Ostrava: Tanger.

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