Products
MAHLE is world leader in the production of engine components. MAHLE products have the best performance under adverse conditions. MAHLE Metal Leve plants in Brazil make use of the most advanced production technologies and equipments. Our engineers work in partnership with clients, projecting components to better assist the specific needs of each application at the lowest cost possible, always purposing to optimize natural resources, fuel savings, durability and reduction of emission levels.Pistons
MAHLE pistons are projected to reach the lowest floating mass, minimizing oil consumption and blow-by, reducing noise and vibration and providing maximum resistance to wear-off.
Some examples of the pistons produced:
- Aluminum alloy pistons for gasoline and alcohol engines, equipped or not with hot plates for thermal expansion control;
- Forged alloy pistons with high resistance against wearing-off;
- Ultra-light, low friction, low noise pistons that tend to replace those conventional pistons from the automobile industry;
- Articulated pistons for Diesel-fueled engines.
MAHLE Bearings are produced for improving performance and offer new options to its customers, through research and development aiming higher load capacity, in order to improve fatigue and wear resistance and thermal stability.
Some examples of bearing produced:
- White alloys or "babbitts", recommended for bushings for which the actuating loads are relatively low
- Sintered bronze bushings (bi-metal and tri-metal), recommended for applications submitted to extreme conditions of loading and pressure, since they present high fatigue strength.
- Cast aluminum alloys with a wide application as automotive bearings for medium and heavy duty engines.
MAHLE offers to its clients, fractured connecting rods – the most advanced technology possible worldwide. The main engine manufacturers are using this type of technology in their most recent developments, both for Otto Cycle engines and Diesel engines. The accountability levels in manufacturing comply with the current demands and future demands of the market, as a final production measuring automatic system, with micron to the tenth and gram to the tenth of precision.
MAHLE is the supplier of fractured connecting rods, integrated to the Power Cell System (Piston / Connecting rod) or as an individual part.
MAHLE produces wet, dry and air-cooled cylinder liners, in large scale.
Our production techniques ensure a high degree of pureness in the metallurgic structure and dimension precision, both in small or large production batches.
The variety of different types of non-alloy, low alloy or high alloy grey cast iron, as well as different plant manufacturing techniques and thermal treatment, enable us to find an individual and optimized solution for each case with diameters that vary up to 280 mm.
Piston pins for gasoline and diesel fuel engines are components that require great precision and quality and integrate the Power Cell, making the connection between the piston and the connecting rods. Severe mechanical resistance standards, design, steel quality and dimensional tolerances must all be rigorously followed.
MAHLE produces piston pins according to the DIN 73126 standard and also according to the specific requisites of our clients, through cold-forming and drilling process with canon drill.
Special types of pins are produced in various different forms and we are apt to manufacture small and large batches, with external diameters varying from 6 to 65 mm.
MAHLE manufactures roughcast, machined and assembled camshafts.
Chilled iron camshafts are cast from high pureness, non-alloy or low alloy grey iron, with laminated graphite or nodular.
Chilled nodular cast iron is developed to fulfill the applications of Otto cycle or Diesel engines.
Assembled camshafts possess known advantages such weight reduction and provide an increase in stiffness and resistance.
The valve tappets, just like the valve rockers, are subjected to special tribologic requirements. The chilled cast iron has been used for many years due to its excellent properties.
Thermal treatments are done in equipment that enables to comply with all client specifications. This way, we are able to offer phosphate, nitrated, nitro-carburet and tempered tappets.
Rocker arms and elements following cames must comply with the most severe resistant and stiffness standards. The nodular cast iron may be used to replace the steel-forged rocker arms with reduction of the product’s final cost.
The rocker arms may be supplied rough, semi-plant manufactured or totally finished, including the bush and insert, according to each particular case.
Set of rocker arms may be supplied fully assembled with all the components.
The modern fuel injection systems require an extremely homogeneous fuel flow, without pulsations and above all, clean in any engine functioning condition.
MAHLE Metal Leve fuel filter modules may be made out of fully recycled materials and have water separator and fuel heater or cooler.
The filtering elements, known as ecologic elements, are easily replaced without fuel spilling, and may be fully incinerated.
High quality air filters ensure that the wearing-off of the motor components, caused due to the entering of dust in the admission air will no longer be a problem.
The heart of an air filter is the filtering element manufactured with high quality cellulose fibers. The impregnation of special resins produces the desired quality, translated into resistance under high temperatures and humidity conditions.
The oil filters are responsible for the task of retaining the dirt of the engine lubricant oil which caused the premature wearing-off of the bearings. The high quality oil filters assure that the engine wear-off would be avoided and that the quality of the oil would be preserved.
The oil filter modules optimize the use of reduced spaces, counting on safety and lubricant oil pressure and temperature monitoring devices.
MAHLE Metal Leve manufactures armored filters with integrated safety valve, as well as, ecological filter which discarding of the filtering element with lower oil quantity is not harmful to the environment.
The cabin air filter is assembled in the circulation air system of the passengers’ seating area and removes up to 99.5% of the particles contained in the external air, including dust, pollen, soot, and tire latex fragments.
The MAHLE Metal Leve Cabin Air Filters protect passengers from unpleasant odors, as well as from toxic gases and vapors present in the external air. Even high concentration of ozone in the air is reduced to non-harming levels through that process.
Activated carbon canister are assembled in the fuel supply system, avoiding the escape of fuel vapors to the environment.
The filter absorbs those vapors, taking the fuel back to the tank.
Oil mist separators remove the oil moved by the blow-by gas and return it to the carter and, many times, integrate a pressure control valve of the carter.
That clean gas is then directed to the engine’s air intake system, returning to be part of combustion and avoiding pollution that would be caused by its unloading into the atmosphere. The oil mist separator is part of the admission modules complex developed and supplied by MAHLE Metal Leve.
MAHLE produces and sales small, medium and large-size structured sinterized components, made out of iron and steel powder, in many cases, replacing the cast and forged components and bringing advantages.
- Engine components
- cam shaft pulleys and cam shaft sprockets
- crank shaft pulleys and sprockets
- pulleys and water pump rotors
- sensor rings
- bearing caps
- oil pump gears and rotors
- Transmission components
- synchronizing hubs
- shift forks
- Hermetic compressor components
- pistons
- conrods
- valve plates
The MAHLE rings combine geometrical accuracy with high-tech base and coating materials, providing a reduced wear, high resistance against scuffing, low friction, and high conformability.
A complete portfolio of compression and scraper rings is offered by MAHLE, which can be applied to both Otto and Diesel engines, with diameters from 25 to175 mm and width of 1.00 mm and above. Intending to meet the increasing demands of modern engines where low fuel and lubricant oil consumption is expected aiming not only at a reduction of maintenance costs, but principally to meet the increasingly strict legislation on gases emission, rectangular, semi-trapezoidal and trapezoidal rings are employed, especially designed for each application.
MAHLE also has a wide range of options for oil control rings. Steel made three pieces oil rings for Otto engines are produced and they can be chrome or nitrate coated, depending on the requested application and durability. The two pieces oil rings are recommended for high-performance Diesel or Otto engines and they can be produced both in gray or nodular cast iron and in steel (I Shaped rings), and they can also be chrome or nitrate coated. Special configurations, such as 2.00-mm width two-pieces oil rings, made of cast iron alloyed with niobium carbides and/or conic contact faces (lands) are used when necessary for reaching requisites of, for example, more conformability, less friction or shorter run in period.
MAHLE has a complete range of base materials in gray, alloyed nodular cast iron produced with the most recent casting technology presently available. The carbon and stainless steel strips are acquired from world leading suppliers in this technology. The criterion for selecting the material is based on engine cost and performance, assuring total satisfaction to the customer.
The coatings and surface treatments of MAHLE rings assure a reduced wear and high resistance to scuffing, associated with a low cylinder wear and properties favorable to lubrication of rings. Nitrided steel and cast iron, chrome-based coatings (Hard Chrome, Channel and Ceramics) and molybdenum (Regular Moly and Moly Cermet sprayed by plasma), HVOF (High Velocity Oxygen Fueled) and PVD (Physical Vapor Deposition) have been developed for overcoming the most severe requisites of the engine durability and reduction to the run in period.
In order to assure flexibility and just-in-time delivery, the manufacturing process used by MAHLE is based on the most recent production concepts such as cells and mini-plants. The free-form machining process is performed through double cam when turning cast iron rings or computerized numerical controlled (CNC) coiling of steel wires, providing MAHLE rings with an excellent sealing and performance during run in and engine life. The CNC grinding of the barrel contact face, the laser marking and the error-proof (foolproof) system are extensively used.
Care for environment is considered since the earlier stages of new projects, and this is the vision shared by both the stockholders and the company’s employees. The constant research on “clean” technologies provides a high-quality working environment in addition to an excellent interaction with the community.
