Motorsports

We offer a complete range of thermal processing services to the motorsport industry from NASCAR to Formula 1. Racing teams require advanced performance and look to the world’s leading thermal processing company for advanced service and support.

Gearbox casings

At the highest levels of motorsport, titanium is often the material of choice owing to its strong, yet lightweight, properties. In the gearbox of a formula 1 car, where optimum performance is paramount, strength and weight are key considerations. Frequently, titanium components are electron beam welded, and sometimes subsequently vacuum heat treated, for the assembly of extremely complex shapes.

The use of electron beam welding (EBW) can, for instance, enable designers to create structures whereby it is possible to make rapid ratio changes in gearboxes to suit different grand prix circuits, whilst retaining their integrity as part of the structure of the car. Another area where such structures are used is in the suspension, where complex shapes are again needed to cope with the aerodynamics of the car. Manual welding of such materials is possible, but the creation of large heat affected areas (HAZ), due to the significantly higher heat input needed, is often problematic. EBW, together with vacuum heat treatment, with all its associated benefits provides an optimal solution.

Synchroniser rings

The ability to change gear seamlessly, particularly when controlling huge amounts of power, is key to the overall comfort and safety factor in driving, be it a family saloon or a 1,000 bhp supercar. Synchroniser rings are a key component, synchronising the gears as the driver changes speeds. In a performance car, where gear speed change can mean the difference between winning and losing a race, the synchroniser ring is subject to demanding conditions and needs to be strong and tough.

Therefore, the join between the thin ring and the bulkier gear parts needs to be equally strong. Electron beam welding (EBW) provides this exceptionally strong join, by fusing the two parts together, with no adverse effects on either the fine tooth form of the synchroniser ring or the metallurgy of the gear. This is due to the high energy-density (low heat input) nature of the EBW process. If EBW was not used for such assemblies, the only option would be one-piece manufacture which would lead to associated design difficulties and higher manufacturing cost.

Valve springs

Bodycote help increase engine life during racing conditions by the application of a special surface controlled nitriding technology to race engine valve springs. During a typical race, an engine will cycle in excess of a million times and be operating under extreme conditions of temperature, endurance, wear and fatigue.

As materials evolve, new grades of steels are developed for particular applications. Valve spring material manufacturers have developed a special oil tempered valve spring wire requiring extreme resistance to fatigue and high operational temperatures. When combined with Bodycote’s controlled nitriding technology, fatigue strength and endurance are dramatically increased to greater than a factor of two for optimum race performance.

Other applications for nitrided springs may also include diesel fuel injector and clutch springs.