Using abrasive flow machining, Extrude Hone AFM can improve the internal surfaces of intake runners by moving abrasive polymer media through the manifold under controlled pressure.
The process follows the shape of the passage and can reach surfaces that may be difficult to access using conventional porting tools.
Why Port an Intake Manifold?
The intake manifold is a critical part of engine breathing.
Its job is to distribute air toward the cylinders with as little unnecessary restriction as practical for the engine design.
Manufacturing may leave internal imperfections such as:
- Rough casting texture
- Burrs
- Uneven runner surfaces
- Restricted transitions
- Differences among passages
Porting seeks to improve those areas.
How AFM Improves Internal Runners
The AFM media carries abrasive particles throughout a flexible polymer.
Hydraulic pressure pushes that media through each selected passage.
As the media moves, it conforms to the runner and abrades raised areas.
This means the tool does not need line-of-sight access.
Long runners, bends, and hidden transitions can all be reached if the media can flow through them.
Extrude Hone AFM's established porting information describes AFM as providing more consistent and uniform material removal than hand-only methods on difficult internal passages.Potential Airflow Gains
For suitable intake-manifold applications, Extrude Hone AFM reports airflow improvements of up to approximately 25 percent.
Improved flow may help support:
- Better volumetric efficiency
- Increased horsepower
- Improved torque
- Better cylinder filling
- Improved combustion efficiency
These gains vary according to the engine.
The manifold operates as part of a complete induction, combustion, and exhaust system, so a particular horsepower increase cannot be guaranteed.
Columbus and Ohio Automotive Applications
Ohio has a major automotive manufacturing and supplier base.
Columbus and central Ohio also support performance shops, muscle-car enthusiasts, racing, restoration, diesel work, custom fabrication, and specialty engine machining.
AFM intake manifold porting can serve both performance and production-oriented applications.
Manufacturers may value repeatability, while enthusiasts may be more focused on improving a specific engine component.
Older and Hard-to-Replace Manifolds
Porting may be particularly useful when an original intake manifold needs to remain in service.
Classic, restoration, and specialty vehicles may not have an appropriate aftermarket replacement.
AFM can potentially improve the original component's internal passages while preserving its overall design.
Different Materials Require Different Processing
Many newer manifolds are aluminum, while older designs may use cast iron.
Extrude Hone AFM can adjust abrasive media according to material hardness.Existing company guidance notes lighter abrasion for aluminum and more aggressive media for cast iron.
Controlled Material Removal
For automotive flow-improvement applications, material removal may reach approximately .040 inch, or 1 millimeter, where appropriate.
The exact process depends on runner geometry and desired results.
Repeatable Intake-Manifold Processing
Once tooling, media, abrasive, and pressure have been established for a specific design, Extrude Hone AFM can repeat those conditions on similar manifolds.
That can provide improved consistency for manufacturers, performance builders, or matched applications.
Call (562) 531-2976 to discuss intake manifold porting for Columbus, OH and request a quote.
FAQs
Can AFM improve both surface finish and airflow?
Yes. Smoothing internal surfaces and reducing restrictive areas can improve the condition of the airflow path.
Can cast-iron intake manifolds be processed?
Yes. Suitable cast-iron manifolds can use a media formulation appropriate for the harder material.
Can Columbus customers send parts to Extrude Hone AFM?
Yes. Extrude Hone AFM serves automotive customers throughout the United States.
