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Reduction of development time and improvement in product quality and reliability have been a driving force in the extremely competitive automotive industry. These trends require extensive use of Computer Aided Engineering (CAE) tools coupled with design optimization and analytical robustness and reliability tools. In this paper the Cylinder kit Analysis System for Engines (CASE), a CAE tool for predicting ring-pack performance in an automotive engine, has been integrated with the design optimization and analytical robustness and reliability tool (iSIGHT) for improving ring-pack performance, reliability, and robustness. A prototype engine has been analyzed and design recommendation tested with available manufacturing.

Systems of alloys for liquid phase alloying during sintering were investigated. The solidification range of alloys of Mn-Ni-Cr-Mo-Fe and Mn-Cu-Ni was determined. Alloys with the lowest and narrowest melting range were prepared and atomized in nitrogen. Admixtures of master alloys to water-atomized, forging grade, pure iron powder were sintered at 1232°C (2250°F). After hot forging, these P/M steels exhibited hardenabilities which were 75%-90% of theoretical hardenability, as calculated from the factors for conventional steels. Alloying efficiency was further improved to 85%-100% of theoretical hardenability when additions of approximately 2% silicon and 1% rare earth misch-metal were made to the master alloys. The silicon and rare earth misch-metal additions were used to enhance diffusion and sintering.