This is the BMW N52 engine block. It is made from a combination of magnesium and aluminum. It has an aluminum inner block witch contains the cylinders, water cooling and the main bearings, and the outer shell made of magnesium.
They have improved the process. Used to cast thy he cylinder wall as a single solid block and drop in in a mould then inject mold the magnesium casing around it with the R1 magnesium alloy.
So now the engine blocks are made of aluminium? All this time i thought they were made out of cast iron, i cant believe how the aluminium can withstand that amount of heat that the engine is producing
Aluminium is a way better heat transporter than iron and it's not twisting itself like steel engines do. If you look into your PC, there is an Aluminium CPU cooler, no Copper. Aluminium is a great heat trap, so ideal for engines.
@@Spelter good answer . but I have another question about the sand mold how could it withstand the heat and still keep shape after the alum block been taken off the sand mold.what is the secret behind it ?
@@peterlonter9053 I know it's a year later, but I worked in a foundry briefly and it's one of my favorite things to talk about. These sand molds use resin sand, which is sand mixed with glue, essentially. Sand has a higher melting point than aluminum, so it doesn't get destroyed during the pouring. The resin just smokes off. They don't save the sand in-between castings. The sand is probably shaken or blown off somewhere in this process. A new sand mold is made for each engine.
I like my N54 VANOS twin turbo, now that they have the proper injectors and high pressure pump [post recall] it has been flawless. I hear the quad diesel W57C30T1 is a beast
The jobs given to the robotic arms would be dangerous for a human operator. Lifting a 500 degree casting that weighs 100 pounds over and over and over all day would ruin a person, then the company would have to pay your workmans comp and possibly a settlement. It's just way better to have robots. They do break down and need repairs a lot so there are still jobs we can do that they need to operate.
@@rq9924 well it was, and that's the problem. It's cheaper to buy robots than have some guy ruin himself doing that job. Safety is paramount, and if we can automate dangerous jobs, less people get hurt and those costs aren't passed onto the consumer. Your point is escaping me, I don't see why you would risk a human life over a minimum wage position.
Wait the engine blocks aren’t made out of plastic too. Because I know everything else is. If your buying a bmw you don’t look for rust you look for dry rot.
@@rsbatcrh06 At the first glance I thought it was some kind of deburring process, but surface coating makes more sense. Teaching the robot performing this process had a o be pain in the back.
@@mil3k it's similar enough to painting. Making sure the right overlap is key. Making sure the entire part gets costed eventually, in all those small hard to reach areas, now that's the PITA programing nightmare.
Hvof stands for high velocity oxygen fuel its thermal spraying you spray molten metal onto the block and it prevents wear and tear it will be machined back to leave a thin layer incredibly loud process but looks cool.
The most unreliable motors ever ! All BMW motors have oil leaking problems or pistones problems . Etc ..even for low mileage ! Old BMWs motors were much more reliable than today's ones !
BMW has the I3 model currently available. BMW has invested a few dollars into R&D with 12 new EV models built and manufactured by 2025. This only BMW engine foundry department lol
calizess lol no they also have tons of recalls and so many parts that break before the warranty ends. No one keeps a bmw they bought new after the warranty ends.
That guy from Terminator 2 ended up in someone's car as a block. Probably reved good.
Ended up a 2jz
Lol, funny u.
Yaaah, cud b 😏😏
🤣🤣
This is the BMW N52 engine block. It is made from a combination of magnesium and aluminum. It has an aluminum inner block witch contains the cylinders, water cooling and the main bearings, and the outer shell made of magnesium.
They have improved the process. Used to cast thy he cylinder wall as a single solid block and drop in in a mould then inject mold the magnesium casing around it with the R1 magnesium alloy.
Neither i have a bmw, nor I make engines.. still watching the complete video.. dont know why
Gee they have the Best of Best equipment to make stuff beautiful and clean thank you for Sharing Australia 🌏
No wonder BMWs cost so much. At least 2 robots just to load the aluminium blocks into furnace.
They use robots because it's alot cheaper than human labor dummy... everybody knows that
bmw still cost alot
@@Lastmanontrack Inglots are the same size, no need for flex automation, simpler solutions are possible.
We've got 500 robots just to build the floor pan assy. for 2 Ford models.
@@mil3k adaptablity-future proofing etc etc
A valid point for electrification of the car industry.
Inacreditável. Como pode ter pessoas tão inteligentes? Muito bacana. Parabéns.
É incrível né ,como a tecnologia está avançada 👏
So now the engine blocks are made of aluminium?
All this time i thought they were made out of cast iron, i cant believe how the aluminium can withstand that amount of heat that the engine is producing
Aluminium is a way better heat transporter than iron and it's not twisting itself like steel engines do.
If you look into your PC, there is an Aluminium CPU cooler, no Copper. Aluminium is a great heat trap, so ideal for engines.
@@Spelter good answer . but I have another question about the sand mold how could it withstand the heat and still keep shape after the alum block been taken off the sand mold.what is the secret behind it ?
@@peterlonter9053 I know it's a year later, but I worked in a foundry briefly and it's one of my favorite things to talk about. These sand molds use resin sand, which is sand mixed with glue, essentially. Sand has a higher melting point than aluminum, so it doesn't get destroyed during the pouring. The resin just smokes off. They don't save the sand in-between castings. The sand is probably shaken or blown off somewhere in this process. A new sand mold is made for each engine.
Hey, I want to know that , how are cooling jackets made? , won't there be trapped sand ?
Who knows? At 3:14 minutes they were heating up the moulding?
What BMW models is this engine in? I have the 2000 bmw e39 528i, best in-line six ever.
I like my N54 VANOS twin turbo, now that they have the proper injectors and high pressure pump [post recall] it has been flawless. I hear the quad diesel W57C30T1 is a beast
All I see here is alot of good people out of work.
The jobs given to the robotic arms would be dangerous for a human operator. Lifting a 500 degree casting that weighs 100 pounds over and over and over all day would ruin a person, then the company would have to pay your workmans comp and possibly a settlement. It's just way better to have robots. They do break down and need repairs a lot so there are still jobs we can do that they need to operate.
How do you think k it was done before robots🤔
@@rq9924 well it was, and that's the problem. It's cheaper to buy robots than have some guy ruin himself doing that job. Safety is paramount, and if we can automate dangerous jobs, less people get hurt and those costs aren't passed onto the consumer. Your point is escaping me, I don't see why you would risk a human life over a minimum wage position.
This must have been a few good years back, probably mid 90's
Definitely NOT.
This isnt 25 years old. Maybe 5 years.
Very intresting,
Wait the engine blocks aren’t made out of plastic too. Because I know everything else is. If your buying a bmw you don’t look for rust you look for dry rot.
You've been watching too much scotty kilmer
Whats this plasma - flame spray ? 4:00
Correct. Technical term is Thermal Spraying. Looks like they were spraying Bronze.
@@rsbatcrh06 At the first glance I thought it was some kind of deburring process, but surface coating makes more sense. Teaching the robot performing this process had a o be pain in the back.
I don't know, but I want one.
@@mil3k it's similar enough to painting. Making sure the right overlap is key. Making sure the entire part gets costed eventually, in all those small hard to reach areas, now that's the PITA programing nightmare.
Hvof stands for high velocity oxygen fuel its thermal spraying you spray molten metal onto the block and it prevents wear and tear it will be machined back to leave a thin layer incredibly loud process but looks cool.
How does that sand mould is heated 4:16
It's amazing!
Sand Casting, Lpdc, hpdc, finishing, machining
I want to see the Z3 roadster straight six injected molded R1 magnesium alloy motor block with aluminum inserts.
I wonder what kind of people design these machines and production lines. A lot has to be custom built
Only the tool heads are custom typically....
E30 is the baby.
Never showed the actual raw block casting.
This bothered me also....
19.06 you can see the block cast, you a see the voids fill up
Where does it coming from?
The arts of machine
In the end of the video, the guy hangs the engine block by the cilinders... Hope that brings health to the engine!
Rubs I thought the same thing when I saw that
The block is still not machined yet.
Rubs they insert steel sleeves for the cylinders after machining the block i think .
@@wickedenterprise Nope, they have a coating called Alusil. ;)
Qrozzfyre interesting . did you know that or learn from google after the fact ?
Gasoline?
Wow
うちの会社も自動車部品の鋳造してるけど、金型で作ってるけど鋳造不良が減らなくて・・砂型鋳造は不良少なそうやなぁ。でもこれは大量生産には向いていないやり方やったはず。少量生産向きか
Some of those robots are pretty creepy.
I'm here for a different kind of casting though
C'est vraiment géniale.
I thought iron ingots exists only in games...
The shape of that small amount of aluminum is so overpriced that they can use robots to make the cast work
all them poxy robots and still one bloke for final check .what dose that tell ya
Robots : no medical , no pension , no union , no salary. , no vacation. Pure profit. , batteries included?
No lung damage tho.
What about intial cost and maintenance ???
Made in full Germany
wall-E
The most unreliable motors ever ! All BMW motors have oil leaking problems or pistones problems .
Etc ..even for low mileage !
Old BMWs motors were much more reliable than today's ones !
Bullshit I got a 03 X5 and haven't had any problems my wife's 06 Audi A6 on the other hand has had way more work done to it recently
So much anectodal evidence.
@@mexicanenglishbullterrieri5162 because old X5's had M57 engines that were undestructibles.
ABB & China KuKa :)
The owner of kuka is Chinese but its an german company... Sorry
BMW must quickly unlearn this and learn to make electric motors and battery packs
BMW has the I3 model currently available. BMW has invested a few dollars into R&D with 12 new EV models built and manufactured by 2025. This only BMW engine foundry department lol
Look at all these poor people in the comments 😐 engine problems aren't an issue if youre not a peasant.
Nja... 20 year ago Japan car motor aluminum. Mazda Toyota other model. Aluminum motor Garanted 20 year
how very english of you :))
Sand casting.
Guarantee that block cracks 3 hours after warranty is expired....
Ihr seid abartig... bitte baut doch die Fahrer eurer Autos auch noch selber...
Nja problem this aluminum little hard motor temperature +700 motor end frame result motor defects. Metal motor old BMW model long
We don't speak your language, I suppose.
What?
I think hes saying iron blocks are better, lol idk
Very unreliable cars.
Would've liked to see the machining work done too
Fascinating to watch
Would've like to see more machining etc...
Just showing robots moving the blocks around.
Kind of a waste.
6:00 The sand mold has a piece broken off just near the front. You can compare it with the mold at 7:00
This area is only in the riser area, not at the final casting. No problem for the part.
Technology is amazing.
Looking good, engineer just need to work little bit more on the electronic system. That’s the main problem we have.
So much technology for a disposable plastic car that falls apart the next day after the warranty expires.
calizess lol no they also have tons of recalls and so many parts that break before the warranty ends. No one keeps a bmw they bought new after the warranty ends.
assassinlexx if you want the best cherrys, you choose Audi.
Quit being poor.
This is hardly overuse of robotics because the process is constantly refined. Absolutely fascinating, very impressive.
They don't make it like they used to. Literally
'
machine make it and robot make it...
must be cheaper price tag...
no reason over too much currency tag
You are buying a brand and not a product
Top abbuizzzt 👍👍👍👍
This is so neat!
It's a me.. mario 3:56
Alex G Ok! let's a go!
Viel Kompetenz, Applaus den Deutschen!
Not the new b58 closed deck engine block.
People should be doing most of that work.
Not robots.
Wow...!!! 👍👍👍
what is the process at 4:00, with the uv beam?
Doxie Lain deburring the block with Surface Heat
I don't get it. The sand casting then put that casting into a die casting machine/press? What makes it so you can't sand cast the whole thing?
So THATS WHY BMW’s cost so much ?
Unfortunately for BMW the inline 6 is their greatest and last achievement V8s are terrible
Your crazy
So this is how you make dinosaur running on dead dinosaur juice.