The production of piston forgings is more complex than the casting process and some 80% of our pistons are produced in this way. The main material used is RR58 (2618A). Two other alloys are used, one is a high silicon alloy and the other is a Metal Matrix Composite alloy. The specification of these alloys must remain confidential at the moment.
The forging process requires material to be bought in at closely controlled diameters, this is then cut to billet size and all cut faces machined to a smooth finish. The billet is pre-heated in an air-circulating furnace to a temperature quite close to the operating temperature of the piston crown when the engine is operating at full power. This temperature is critical and cannot be disclosed. This together with tightly controlled speed of the forging process gives a dense and very fine grain structure to the forging. Microstructure analysis of our forgings and that of other manufacturers will highlight this difference. This fine grain structure gives our forgings higher strength and fatigue life. After forging, any excess material is removed and the forgings are then heat-treated followed by wet blast cleaning.
Omega Pistons are individually weighed and batched to within 0.5 grams, which ensures that a set of four will have a tolerance deviation of no more than 2.0 grams.
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