- 2004-2019 STi & 2006-2014 WRX
- Brand: MAHLE Motorsport
- Manufacturer's Part Number: WRX209937I22
- Size: 0.5mm oversized
- Actual Weight: 401 Grams
- Primary Material: 4032 low expansion aluminum alloy
- Pack Quantity: 4
- Bore Size: 100.0mm
- Condition: New Product
The requirements on pistons for gasoline engines have become ever greater over the past few years. The thermal loads have risen as a result of higher power demands. The stresses at average ignition pressures have increased through knock control, direct fuel injection and turbocharging, while high speed concepts have led to an increase in inertia load. MAHLE has responded to these requirements by utilizing longstanding experience and innovative concepts, which continually adapt the existing product program to the challenges of tomorrow.
The MAHLE program for gasoline engines
The piston program for gasoline engines comprises weight optimized aluminum pistons with diameters from 65 to 110 mm for the highest requirements. The pistons are produced from cast or forged, high-temperature resistant aluminum silicon alloys. These alloys and the refined casting technology from MAHLE enable an ideal combination comprising pistons with low weight and high structural strength to be produced: for example the MAHLE ECOFORM pistons. Based on the ECOFORM piston, the next generation of MAHLE lightweight pistons was developed: the EVOTEC piston. The optimized design enables further weight reduction, while increasing the load-bearing capacity.
New challenges - optimum processes
Modern engines with variable valve train or different direct injection concepts require pistons with a complex geometry. This often leads to a higher piston weight due to involved crown shapes. To achieve as ideal as possible a combination of low weight and high stability despite this, the suitable choice of material is just as crucial as an optimum production process. MAHLE utilizes its longstanding development experience to best effect here, both in forging and casting technology.
Improved coating for less friction
The piston skirt for gasoline engines with cast or steel cylinder surfaces is usually coated with GRAFAL at MAHLE. GRAFAL helps to reduce friction and hence increases the scuffing resistance. A further advantage of GRAFAL-coated pistons: They enable a closer fitting clearance which leads to significantly lower engine noise in conjunction with complex piston forms.
For the application in aluminum cylinder surfaces, MAHLE uses the iron particle reinforced synthetic resin coating FERROPRINT. MAHLE's new FerroTec galvanic iron layer is another ongoing development available on the market. The FerroTec technology coats the entire skirt evenly, resulting in improved running properties. These coatings are necessary to enable the combination of aluminum pistons with pure aluminum engine blocks and hence represent an essential contribution to an overall reduction in engine weight.
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