Federal-Mogul announced it has developed the next generation of the Monosteel piston, called Magnum Monosteel. The new design reduces piston mass by up to 7% and includes design features that reduce friction for improved fuel economy and lower emissions, the company said.

The piston currently is in development testing with major global commercial vehicle and engine manufacturers in North America and Europe. Like the original Monosteel piston, the Magnum addresses the increasing thermal, mechanical, abrasion and corrosion challenges placed on heavy-duty diesel engines resulting from stringent emissions regulations. The maker said both the original Monosteel and new Magnum Monosteel have patented dual friction-welded construction, which enables large cooling galleries for superior high temperature resistance and strength to withstand the highest cylinder pressures found in modern commercial vehicle engines.

The key differentiator for the Magnum, however, is its double-band piston skirt design—a first for modern diesel pistons, Federal-Mogul said. The double-band skirt helps to reduce frictional drag and reduces the overall piston skirt area by 40%, making this design feature the primary contributor to the Magnum’s overall friction and mass reduction. Extensive engine testing has shown piston friction reduction of up to 17% compared to conventional steel piston designs, according to the company.

The piston’s double-band skirt also enables better hydrodynamic lubrication as compared to conventional piston skirt designs. The improved lubrication allows for greater piston stability, as well as optimal ring pack performance and durability, Federal-Mogul said.

“With the Magnum piston, Federal-Mogul is again bringing a significant piston architecture innovation to the heavy-duty market through an enhancement to our proven Monosteel design,” said Rainer Jueckstock, Federal-Mogul senior vice president of powertrain energy.

“Like our industry-leading Monosteel piston, the Magnum with its fuel economy benefits is another game-changing technology that provides heavy-duty customers with a more effective solution to the emissions challenges they face. In addition to on-highway applications, the Magnum is well suited for industrial and marine applications, as well.”