Reducing the weight

Connecting rods

The trend in connecting rods is toward lighter weight components. These must withstand even greater power loads despite their low weight. The MAHLE connecting rods were designed with this in mind. The use of higher-strength and innovative materials ensures that MAHLE fulfills the requirements demanded by the market. It should therefore come as no surprise that MAHLE is market leader in the production of forged fracture-split conrods.

The MAHLE connecting rod program
The MAHLE product range comprises connecting rods for passenger cars, commercial vehicles and motorcycles with raw forging weights of 0.3 to 12 kg. Its comprehensive expertise in engine technology makes MAHLE the perfect development and production partner for integral system solutions, also in conjunction with other engine components.

Leadership through fracture-split materials
The increasing cylinder pressures call for changes in the connecting rod's geometrical design—and further development of crackable steel. A strongpoint of MAHLE consequently lies in the raw forging of crackable steel conrods and machining work for connecting rods made from steel and sintered materials. MAHLE develops materials which exhibit significant improvements in important properties: whether with respect to fracture-split and strength or in regard to other economically important factors such as machinability.

Competence in production machining
With the mechanical processing of forged and sinter-forged connecting rods, MAHLE has extensive knowledge regarding optimum production processes for the end product. By abandoning honing as a production process in the connecting rod big end, we have set new trails for working towards even more cost effective solutions.

Advantages through new geometries
One thing applies for today's connecting rods: Less means more. MAHLE achieves significant weight reductions through new component geometries. This includes the development of connecting rod small end from a keystone to a stepped form—with the advantage of a reduction in the overall pin length. With several connecting rods, MAHLE was able to totally dispense of the connecting rod small end bushing through an adapted profiled bore.