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Diesel engine common rail systems are expected to reach higher pressures, which require higher internal fatigue strength of the rail. The primary objective of this study is to improve the rail strength by modifying its structure. In this paper, a prospective rail construction capable of handling higher pressures is proposed. At first, a current generation rail was evaluated for pressure cycle durability, in order to analyze its strength. Then the optimized structure was sought via FEM analysis, which revealed that a flat internal surface significantly improved strength. The results were confirmed by pressure cycle tests.

In cold and heavy snowfall regions such as Europe and North America, substantial quantities of rock salt are spread on roads for the prevention of icy road surfaces and car slipping so that winter transportation can be assured. Such salt however promotes corrosion not only of automotive bodies but also of automotive parts. Automotive piping is no exception, leading to the need for new surface treatment. With a view toward finding a promising substitute for Zn plating which has been used for many years, various high corrosion resistance surface treatments have been compared. This paper reports the results of the comparison.