AWA Forged Composites™ Connecting Rods Capable of Over 12,000 Horsepower With Far Less Fatigue Than Aluminum!
Our goal is to build the finest connecting rods money can buy. We use our patented and latest technology in composites available at any price. Our connecting rods were extensively designed and tested over five years in the making with a comprehensive computational analysis in conjunction with and verified by a prestigious aerospace engineering firm, ATA Engineering, Inc. who boasts an extensive knowledge of advanced structural composites resulting in one of the most comprehensive FEA/FEM (finite element analysis/ finite element method) and comparative analysis ever conducted on an aluminum, titanium and composite connecting rod. Our proprietary Sheet Matrix Composites (SMC’s) are lightweight, ultra high strength, high temperature fiber reinforced composites capable of withstanding a wide range of fatigue, structural, thermal and environmental conditions. Using the most advanced materials allows us to construct components that can withstand the harsh environments presented inside of a race engine, and the corresponding strength and fatigue resistance reliability necessary to justify the cost. We employ the capability to dramatically change the material properties through customization of fiber types, fiber charge patterns, fiber architecture, resin system, fiber spacing, and fiber volume. Our unique patented design/technology is near isotopically stable at all temperatures in a cycle of operation inside an internal combustion engine.
AWA Forged Composites™ with our patented “ARP” connecting rod “T” bolt allows for in excess of 18,000 lbs of clamping pressure per bolt. Further specialization is achieved through the integration of vertical plane steps, chamfered corners, and selective fiber placement, providing enhanced transitional performance. While all SMC’s take advantage of the combined property benefits of a tailored fiber and matrix system, only our exclusive supplier’s solution uses a proprietary weaving technique that improves material performance by using unimpeded fibers and placing fiber reinforcements in unidirectional directions, even at equal fiber volumes.
The unparalleled strength provided by the unimpeded discontinuous and unidirectional fiber reinforcement results in unique benefits that are made available only in our components. AWA has yet another patented process which seals and mitigates the inherent problem of “fluid uptake,” (hygroscopic) which as we know, would be the end of any laminate product. Each connecting rod is custom made to order specifically for the customer/builder. ATA Engineering (independent aerospace engineering firm) concluded that, *“Analytical bearing pressure for a engine up to 4000 horsepower is substantially improved with AWA’s composite connecting rod, so there is less concern about any adverse effect on bearings when switching from an aluminum rod to AWA’s composite connecting rod.” The aforementioned was referencing our “gen 1 composite rod.” Our new gen 2 rod is substantially improved in design, fiber charge pattern and composition. AWA Forged Composite connecting rod is engineered to allow for the wrist pin to run directly on the surface of the rod, therefore eliminating the need for bronze bushings. Our fuel rod is about 640 grams, approximately half of the weight of a comparable aluminum connecting rod. Utilizing our 7.106 composite rods and 1.155 x 3.300 wrist pins allows engine builders to remove a whopping 19.1 lbs of rotating mass over the incumbents! The lead time is approximately 30 days from the placement of order unless otherwise noted. Our material has certain size limitations, all applications are custom ordered. Connecting rods will be available beginning January 2020.
Tech Talk #93 by David Reher, Reher-Morrison Racing Engines:
“Aluminum rods have been the first choice in unrestricted classes for decades, from top fuel to the fast sportsman eliminators. Aluminum is lightweight, easily machined, and serves as a shock absorber to cushion loads on the crankshaft. Its downsides are also well documented- aluminum has a shorter fatigue life than steel and requires larger cross sections to achieve comparable strength. If a customer wants to make 400 runs between engine rebuilds, I’ll steer him away from aluminum rods.”
“The reality is that an engine with less rotating mass will accelerate faster, which tips the scale in favor of the lightest rods in these applications.”
“Now I know that the wrist pins must be rigid to prevent damage to the connecting rod and piston.”
*Metallic and Composite connecting Rod Structural Analysis-Bearing Pressure Calculation (By ATA Engineering, Inc.) AS9100 Certified. For more information and Case Study: Connecting Rods Case Study- 102018
NEXT GENERATION TECHNOLOGY
AWA has identified a need for lightweight pushrods in a race engine. The inherent need for lighter yet stronger components has led our team of engineers to look at the current design of a racing pushrod. Our unique patented design shapes our ultra high modulus material to form using our proprietary weaving technique that improves material performance by using unimpeded fibers and placing fiber reinforcements in three or more directions, even at equal fiber volumes. The unparalleled strength provided by the unimpeded fiber reinforcement results in unique benefits that are made available only in our components. Our pushrods in comparison to tool steel, are 83% lighter and 3 1/2 times stiffer! We measure stiffness on and off axis at 1400 pounds of valve spring pressure over a two inches of travel with less than .0001 of deflection VS a solid tool steel pushrod at .500 O.D. with . 0002 of deflection! Our composite rods are known to translate “less chaos” to the valve-train and mitigate unwanted harmonics away from the valves. Currently we’re only building 0.500 O.D. with ball and cup ends, others sizes and styles to follow soon. Stay tuned to an announcement on our website.
- Ultra High Modulus | 94 msi, 414 ksi | Stiffest pushrod available – Great thermal conductivity – higher strength fibers in the 90° orientation to create a well-balanced and functional composite structure, with radial and axial loads in excess of most incumbent metal materials. (see graph below)
This patented design integrates the use of aerospace grade titanium inserts and conventional tips (application specific). AWA has yet another patented process which seals and mitigates the inherent problem of “fluid uptake,” (hygroscopic) which as we know, would be the end of any laminate product. All pushrods are custom ordered and some sizes are available in elliptical application specific requirements. Pushrods will be available January 2020. Stay tuned for a distribution announcement soon!
AWA has recognized the need for a lightweight structurally strong components, chief among them is a bellhousing. We noticed that the aircraft industry has safety standards for the containment of turbine impeller blades which rely on composite materials for our travel safety and security for years, so why not our composite for the choice of a racing bellhousing. We recently revealed our 7 pound carbon fiber bellhousing at the 2018 SEMA and PRI trade shows and won the prestigious GLOBAL MEDIA AWARD at both events (see additional photos on our “AWA IN ACTION” page)!
Distribution, availability and SFI certification are now in testing phase. Stay tuned for a distribution announcement soon! PATENT PENDING
Composite/HYBRID Wrist Pins
Our composite wrist pins are approximately 132 grams at 1.155 O.D. X 3.300 length, with greater sheer and fatigue strength and “more rigid” than tool steel at a fraction of the weight!
Compared to 3.300 O.D. X 3.300 length tool steel at 319 grams, our wrist pins are approximately 184 grams lighter!
(Stay tuned for photos and full description. PATENT PENDING)
AWA Forged Composite™ Pistons
Our soon-to be released AWA Forged Composite™ pistons and subsequent research and modeling has revealed some astounding performance figures. In addition to being slightly lighter than the incumbent aluminum, our research has shown that we experienced the ability to achieve higher air-fuel ratios resulting in greater torque, horsepower and fuel economy simultaneously! The above photos represent an early iteration of our design, which has led us to the development of the worlds first production full carbon composite piston. We anticipate release in Q2 2020.
Carbon Composite Wheels