Yamaha has developed a new aluminum die casting technique, which “can result in about a 30% reduction in part weight and 80% reduction in the number of parts” required for a given application. Called “CF Aluminum Die Casting”, the technique reduces the “air-intrusion rate”, which is the cause of air bubbles in cast aluminum, to approximately one-fifth that of conventional die casting. According to Yamaha’s extensive press release, this technique also results in a significant reduction in cost.
The reduction in the number of parts results from the ability to cast thin sections (which retain sufficient strength), as well as sharp curves (normally impossible with traditional casting techniques). Additionally, the “CF” method results in aluminum that is strong enough to be welded, unlike conventional die-cast aluminum.
Since the 2002 YZF-R1 is 40% aluminum by weight, according to Yamaha, and much of this is cast pieces, overall weight reduction in future Yamaha motorcycles could be very significant. For those of you interested in this exciting new technology, take a look at Yamaha’s excellent and detailed explanation on the English version of their Japanese web site here.
