In the field of engine-related products, optimum solutions can only be achieved by carefully tuning the individual systems components. For a number of years, MAHLE has therefore increasingly focused on more intense analysis of entire systems rather than individual components. An all-inclusive analysis of the interactions is becoming increasingly important for optimizing running behavior as well as friction, wear and lubrication - particularly when it comes to the design of the components of the power cell unit (piston, piston rings, piston pin, cylinder liner, and connecting rod with bearings). We achieve this by adapting simulation tools, for example. Taking the design interactions for all relevant components - e.g., piston, piston pin, and connecting rod - into account, improved simulation approaches allow us to develop weight-optimized solutions, which could not be implemented if the individual components were analyzed separately.

In addition, we are now successfully using computer simulations for analyzing wear behavior. This is a newly developed simulation method, which takes the surface geometry and roughness of piston rings and cylinder liners into consideration. By developing innovative coating concepts for our materials, we optimize the wear resistance of surfaces to meet higher requirements - for instance, in terms of reduced lubrication, oil dilution, and operating temperatures. In the development process, we use modern wear testing methods in the laboratory. Innovative examples include our PVD coatings for piston rings and piston pins as well as lead-free bearing coatings.

Enhanced load-bearing capacity and operational safety
In the area of materials, our high temperature-resistant aluminum alloys for gasoline and diesel pistons have become successfully established on the market. With optimized piston cooling, we offer a means to further increase the load-bearing capacity of pistons. Over six million of our passenger car diesel pistons with cooled ring carriers are now in use - this unique cooling technology is increasingly employed in new projects for future high-performance diesel engines in passenger cars.