Porsche will print pistons for the 911 GT2 RS engineJuly 14, 2020
New parts made using 3D printing technology will add 300 hp models. power.
The German automaker has begun to produce 3D-printed pistons for its 911 GT2 RS, which are lighter, tougher and have an integrated and closed cooling system, which leads to an increase in power and efficiency. The automaker, in partnership with German car parts suppliers Mahle and Trumpf, printed pistons to demonstrate that engine parts can be engineered to work under high pressure and heat. In fact, after the pistons were printed, processed and analyzed for defects, they were placed on the engine test bench and simulated a 200-hour cycle without any problems.
Mahle created a high-purity metal powder that fits in a Trumpf printer, using laser beams to heat and melt the powder one layer at a time. As a result of this, the piston has become not only 10% lighter, but also has a higher rigidity than a traditional forged part. It also has an integrated cooling system.
This integrated cooling system cannot be added to the piston using traditional forged production methods. Thanks to additive manufacturing, the temperature in the area of the piston ring is reduced by more than 20 degrees Celsius.
According to Frank Ickinger of Porsche’s Advanced Drive Engineering Department, “This allows up to 30 horsepower. from a 700-horsepower biturbo engine while improving efficiency. ” However, the automaker is not quite ready to start 3D printing of parts for cars of the usual series. According to Ickinger, it will take about 10 years. Porsche currently offers 3D-printed bucket seats for the 911 and 918 and some parts for the classic Porsche. Future customized products for customers will begin to be prepared in about 2-3 years. For small-scale production with 3D-printed parts, this will be about five years.
When 3D-printed pistons hit the real 911 GT2 RS, which will be released on the track, Porsche does not yet say, “We are just exploring this topic,” Ickinger said. But when they do, they can be connected to other mechanisms that were created using lasers and powder instead of forged ones.
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