Lightweight Pistons Could Further Enable Engine Downsizing

A new, high-strength lightweight aluminum piston, the Advanced Elastoval II developed by Federal-Mogul, has been conceived to improve power density and efficiency of forced induction and directly injected internal combustion engines, such as Ford’s line of EcoBoost motors.

The new piston incorporates complex curved side panel forms, with asymmetric geometry and multiple weight reduction pockets. In layman’s terms this enables around 20 percent in weight savings, while resulting in a piston design that can withstand significantly higher cylinder bore pressures that occur late in the engine’s combustion cycle.

Federal-Mogul says that power output levels of internal combustion engines are likely to increase in the coming years and along with them, peak cylinder pressures, especially on engines that run on E100, compressed natural gas or other fuels.

The Advanced Elastoval II piston; is currently being evaluated by several manufacturers, with a production vehicle introduction (in a European passenger car application) slated for this fall.

Green Car Congress


  • Van

    Can you imagine the great mileage improvement is the put diamond rings on them like GM. :)

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  • AP

    Sometimes it’s a lot of little things that improve fuel economy, not just one “flashy” system.

  • Al Bunzel

    I agree with AP that every little bit counts. I wonder if any R&D efforts have been put into lightening and strengthening the gudgeon pin and conrod?

    The car industry should make more use of lighter parts in cars such as carbon fiber body panels and structures. The weight saving would be enormous and could possibly reduce car weights by one-third of today’s equivalent cars. Imagine how much fuel (for gas cars) or electricity (for electric cars) or both (for hybrids) would be saved? Look at F1 cars. Their mass is around 1411 lbs (640kg) and they are very safe cars in a crash.

    Also, if the car industry put the same effort into Electric Vehicle technology as they are doing with gas engines, we probably would have Electric Cars that recharge quickly, travel several hundred miles on a single charge and have smaller, lighter, high energy density batteries.