EVER WONDERED WHAT PISTONS A FORMULA ONE CAR USES? WONDER NO MORE, AND PREPARE FOR A SHOCK.
Unless you’re one of those car people into modifying and making cars faster, you’ve likely never given much thought to the pistons in your car. For the rest of us, things like high compression, forged, rings, gaps, squish and more is something we think about and talk about often. Original OEM pistons in some cars can handle a lot of punishment, but when they reach their threshold then it’s time to fit aftermarket pistons that are stronger, lighter and as expected, a lot more expensive. They’re also one of the engine components from the first car to now, but there have been loads of design and material changes along the way. In the late 1800s and early 1900s, pistons were typically made from cast iron due to its availability, durability, and good heat resistance but they were heavy and only suitable for the low-revving engines of that era. Aluminium pistons are popular, and they entered the fray as far back as the 1920s. As engines became more powerful and revs increased, the need for lighter pistons became apparent and so aluminium alloys began to replace the heavy cast iron components. Aluminium pistons were much lighter, reducing reciprocating mass and allowing engines to rev higher. This change was critical in racing, where every ounce of weight mattered. These pistons were first used in aviation and racing engines before the technology filtered down to mass-produced cars. Companies like Mahle and Alcoa were pioneers in developing aluminium piston technology. They figured out that aluminium pistons had issues with thermal expansion, so designs had to incorporate expansion slots or steel struts to control their shape at high temperatures. The post-war era of the 1950s saw new advancements in both materials and manufacturing techniques with the development of high-silicone aluminium alloys to help reduce thermal expansion and increased wear resistance. Forging, rather than casting, became more commonplace in racing pistons, as it allowed for stronger and lighter pistons by refining the grain structure of the aluminium.
Coatings also began to emerge, particularly in racing, to reduce friction, improve lubrication, and protect the piston from thermal damage. Racing engines, particularly in Formula 1 and endurance racing, were pushing the boundaries of what pistons could endure, leading to innovations that would later filter down to road cars. From the 1980s onwards, advancements in computer-aided design and computer-aided manufacturing allowed engineers to design pistons with much greater precision and this led to pistons that were not only lighter but also optimized for better combustion, with carefully designed crowns to improve the fuel-air mix. In racing, this era saw the introduction of exotic materials and processes. Titanium pistons were experimented with, particularly in motorcycles and Formula 1, due to their strength and lightness, but their high cost and manufacturing complexity limited widespread use. Ceramic coatings also became more common, offering better thermal insulation and reduced friction. The 90s and 00s saw the rise of hypereutectic pistons made from aluminium-silicone alloys with a high silicone content, offered reduced thermal expansion, improved wear resistance, and were lighter than previous designs. They became especially popular in high-performance road cars and endurance racing. Today’s racing pistons are often forged, with intricate designs that optimize weight distribution, strength, and cooling. 3D printing technology is also gaining traction because it allows complex designs that can significantly improve performance. A decent set of forged aftermarket pistons for a 4-cylinder car can set you back a cool R15,000. Proper dragster pistons can cost a cool $1,000 each, or around R17,000, and you usually need eight of them. And then there’s Formula One, the pinnacle of automotive engineering. Here pistons can cost silly money, like really mad money. As per this awesome video, the R&D and manufacture of an F1 piston can cost as much as $65,000. Each. That’s a mere R1,161,000. For a full set for an F1 car, you’re looking at R6,966,000. Daaaamn.
Take a look at the YouTube video from Driver61 who also wondered what went into the manufacture of a Formula One piston, but he did something about it and went on a factory tour with Cosworth to get all the juicy information and visuals: How Formula 1 Pistons Are Made (I went to the factory) | Driver61
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