Intelligent Composites has worked with industry partners to test preliminary hybrid material compositions in other vehicular components. These findings indicate that our IC Hybrid material will be a valuable material to use for cylinder liners inside of internal combustion engines would result in an increased service life, and a doubled maintenance interval.

The Intelligent Composites hybrid liners could allow for up to a 10% increase in horsepower compared to the current Nikasil coated aluminum or cast iron liner technology. Advances in the processing of this material developed by Intelligent Composites allow for production of self-lubricating composite liners at 25% lower cost per unit than Nikasil-coated aluminum liners. This would permit an Original Equipment Manufacturer (OEM) to design an engine that meets or exceeds performance goals at lower cost. Compared to cast iron liners, our liners offer a 60% reduction in weight resulting in a lighter weight engine, leading to a faster vehicle and better fuel economy.

Selected physical and thermal properties of hybrid composite compared to other materials.

A356-10SiC-4Gr (IC Hybrid) Al-9Si-20SiC A356 Gray cast iron
Density (g/cc) 2.75 2.77 2.685 6.0-7.35
Hardness (HRB) 70 77 55 75-150
UTS (MPa) 270 320 250 100-450
Elongation (%) 0.55 0.4 5 0.1-0.3
Cp (J/gK) 0.87 0.913 0.963
K (W/mK) 134 184.9 150.6 36-57
CTE (30-500C) (μm/m-K) 20.1 21.4 26.4 13

Table 3: Thermal Properties of alloys and Al -9% Si- 20 vol%SiC MMC compared with A 356 and Cast Iron.

10S:4G Exp. 6S:3G Exp. 5A:3G Al – 9% Si -20 vol% SiC A356 Grey Cast Iron
Specific Heat J/gK 0.871 0.887 0.871 0.837 0.963 0.38
Thermal Conductivity W/mK 134 157 111 184.9 150.6 -50
Thermal Expansion 0-500C ppm/K 20.1 21.2 17.8 21.4 22 12