[Robert91RS]

Originally Posted by radz282003

Hypereutectics are better now, I believe. They still aren't as good as forged slugs in the LS9, but they're better than the past.

Originally Posted by Camaro509

Someone with more knowledge about this please set me straight, but I thought
Hypereutectic pistons were inferior to forged pistons where higher power out-put
was concerned? That they couldn't handle some of the power add-ons as well as forged pistons could...

This Wiki quote is very informative.

“Hypereutectic” refers to a metallic alloy which has a composition beyond the eutectic point. In materials science, the word eutectic refers to a specific ratio of chemical composition at which the constituent elements will form a single, homogeneous phase when cooled. Above or below this ratio, separate chemical phases will form during cooling due to insolubility of one constituent in the other. Most metals are not eutectic, and have different phases present in their cooled form. Hypereutectic pistons are made of an alloy of aluminum which has much more silicon present than is soluble in aluminum at the operating temperature. Hypereutectic aluminum has a lower coefficient of thermal expansion, which allows engine designers to specify much tighter tolerances.

The most common material used for automotive pistons is aluminium due to its light weight, low cost, and acceptable strength. Although other elements may be present in smaller amounts, the alloying element of concern in aluminum for pistons is silicon. The point at which silicon is fully and exactly soluble in aluminum at operating temperatures is around 12%. Either more or less silicon than this will result in two separate phases in the solidified crystal structure of the metal. This is very common. When significantly more silicon is added to the aluminum than 12%, the properties of the aluminum change in a way that is useful for the purposes of pistons for combustion engines. However, At a blend of 25% silicon there is a significant reduction of strength in the metal, so hypereutectic pistons commonly use a level of silicon between 16% and 19%. Special moulds, casting, and cooling techniques are required to obtain uniformly dispersed silicon particles throughout the piston material.

Advantages
Most automotive engines use aluminium pistons that move in an iron cylinder. The average temperature of a piston crown in a gasoline engine during normal operation is typically about 300C (600 degrees Fahrenheit) and the coolant that runs through the engine block is usually regulated at approximately 90C (190 degrees F). Aluminium expands more than iron at this temperature range so for the piston to fit the cylinder properly when at a normal operating temperature, the piston must have a loose fit when cold.

In the 1970s increasing concern over exhaust pollution caused the U.S. government to form the Environmental Protection Agency (EPA) which began passing legislation that forced automobile manufacturers to introduce changes that made their engines to run cleaner. By the late 1980s automobile exhaust pollution had been noticeably improved but more stringent regulations forced car manufacturers to adopt the use of electronically controlled fuel injection and hypereutectic pistons. Regarding pistons, it was discovered that when an engine was cold during start-up, a small amount of fuel became trapped between the piston rings. As the engine warmed up, the piston expanded and expelled this small amount of fuel which added to the amount of unburnt hydrocarbons in the exhaust.

By adding silicon to the piston's alloy, the piston expansion was dramatically reduced. This allowed engineers to specify a much tighter cold-fit between the piston and the cylinder liner. Silicon itself expands less than aluminium but it also acts as an insulator to prevent the aluminium from absorbing as much of the operational heat as it otherwise would. Another benefit of adding silicon is that the piston becomes harder and is less susceptible to scuffing which can occur when a soft aluminium piston is cold-revved in a relatively dry cylinder on start-up or during abnormally high operating temperatures.

The biggest drawback of adding silicon to pistons is that the piston becomes more brittle as the ratio of silicon is added. This makes the piston more susceptible to cracking if the engine experiences pre-ignition or detonation.

Performance replacement alloys
When auto enthusiasts want to increase the power of the engine they may add some type of forced induction. By compressing more air and fuel into each intake cycle, the power of the engine can be dramatically increased. This also increases the heat and pressure in the cylinder.

The normal temperature of gasoline engine exhaust is approximately 650C (1200F). This is also approximately the melting point of most aluminium alloys and it is only the constant influx of ambient air that prevents the piston from deforming and failing. Forced induction increases the operating temperatures while “under boost” and if the excess heat is added faster than engine can shed it, the elevated cylinder temperatures will cause the air and fuel mix to auto-ignite on the compression stroke before the spark event. This is one type of engine knocking that causes a sudden shockwave and pressure spike, which can result in an immediate and catastrophic failure of the piston and connecting rod.

The “4032” performance piston alloy has a silicon content of approximately 11%. This means that it expands less than a piston with no silicon, but since the silicon is fully alloyed on a molecular level (eutectic), the alloy is less brittle and more flexible than a stock hypereutectic “smog” piston. These pistons can survive mild detonation with less damage than stock pistons.

The “2618” performance piston alloy has less than 2% silicon and could be described as hypo (under) eutectic. This alloy is capable of experiencing the most detonation and abuse while suffering the least amount of damage. Pistons made of this alloy are also typically made thicker and heavier because of their most common applications in commercial diesel engines. Both because of the higher than normal temperatures that these pistons experience in their usual application and the low-silicon content causing the extra heat-expansion, these pistons have their cylinders bored to a very loose cold-fit. This leads to a condition known as “piston slap” which is when the piston rocks in the cylinder and it causes an audible tapping noise that continues until the engine has warmed to operational temperatures. These engines should not be revved when cold, or excessive scuffing can occur.

Forged versus Cast
When a piston is cast the alloy is heated until liquid, then poured into a mould to create the basic shape. After the alloy cools and solidifies it is removed from the mould and the rough casting is machined to its final shape. For applications which require stronger pistons, a forging process is used.

In the forging process the rough casting is placed in a die set while it is still hot and semi-solid. A hydraulic press is used to place the rough slug under tremendous pressure. This removes any possible porosity and also pushes the alloy grains together tighter than can be achieved by simple casting alone. The end result is a much stronger material.

Hypereutectic pistons can be forged but typically are only cast because the extra expense of forging is not justified when cast pistons are considered strong enough for stock applications.

Aftermarket performance pistons made from the most common 4032 and 2618 alloys are typically forged.