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There are several all-aluminum cylinder blocks. A typical example is a mono-block cylinder of alusil alloy produced by low pressure die casting. This material's resistance to abrasion and seizure, however, is not satisfactory for motorcycle; in addition, long processing time is another disadvantage. To cope with these problems, the authors developed a light and highly productive all-aluminum cylinder block with a cast-in liner through die casting. The liner is made from powder metallurgy composite (PMC) with 3 to 5 % alumina and 0.5 to 3 % of graphite additives. The PMC reconciles abrasion resistance and machinability. The hardness deterioration of the composite due to the heat at die casting is avoided by using heat-resistant rapidly-solidified powders, made from an aluminum-silecon-iron alloy, for the matrix.

We have developed new P/M Al-Si wrought alloys having high strength and high wear resistance for use in the rotors and vanes of rotary car air conditioners. In addition, combined with the development of near-net-shape extrusion technologies, through a joint project with Diesel Kiki Co.,Ltd., we have succeeded in the world's first mass production of rotors made of P/M aluminum wrought alloy. In this paper, the properties and production technology of vanes and rotors made with new P/M Al-Si wrought alloys are presented.