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With Continuous increase in demand to reduce weight is forcing Automotive Designers towards finding ways to explore new materials for the Engine components. Currently, Aluminum, Thermoplastics and Composites are widely used in Engine application. This paper examines the potential of a Magnesium alloy Front Cover designed to replace the Cast iron Front Cover in a Light duty Diesel engine. In presented study, a Cast iron Engine front cover is re-designed for Magnesium alloy and components developed. Further Magnesium alloy component tested at vehicle level and it has been demonstrated that a magnesium alloy Front cover can achieve key functional requirements such as Structural durability, Sealing, NVH, while providing substantial Weight saving.

Automakers are being subjected to increasingly strict fuel economy requirements which led OEMs to focus more on Light weighting and Energy efficiency areas. Considering the aforesaid challenges, efforts have been taken in Light weighting of mounting bracket for Engine application.This paper deals with conversion of Engine accessory bracket from Aluminum material to Metal Matrix composite (MMC). In Design phase, existing bracket has been studied for its structural requirements and further Bracket is designed to meet MMC process requirement and CAE carried out for topology optimization and Structural integrity. Finally observations and results were compared for Existing design and Proposed design and further optimization proposed.