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The advent of more efficient direct injection turbocharged engines has increased the need for higher performance connecting rods, able to withstand in particular higher compressive loads in operation. In this respect, new high strength materials for powder forged connecting rods were developed and introduced in production with excellent results. Among them, HS170M is currently used to manufacture connecting rods for several high performance engines, which not only have higher strength, but have less variation in their mechanical properties. The results of numerous benchmark studies have shown that powder forged connecting rods manufactured with HS170M are stronger than their steel forged counterparts manufactured with microalloyed steels, are easier to machine and fracture split, and represent a cost effective way to manufacture this important high reliability automotive component.

An ultra-lightweight piston and conrod without small end bush, combined with a ring pack designed for minimized friction is analyzed and demonstrated as an optimized power cylinder system in a high performance gasoline engine. Component and system analysis for optimizing the design, materials used and design features are reviewed, along with durability, NVH and friction testing results. Results are compared to other benchmark power cylinder system components for weight, performance and value.