Using abrasive flow machining, Extrude Hone AFM can smooth internal intake passages and reduce restrictive areas by forcing abrasive-filled polymer media through the manifold.
The process follows the runner's actual geometry and can reach deep surfaces that may be difficult to access using conventional porting tools.
Why the Intake Manifold Is a Strong AFM Candidate
The intake manifold is one of the most influential components in an engine's airflow pathway.
Manufacturing can leave intake runners with:
- Rough cast texture
- Burrs
- Uneven internal surfaces
- Abrupt transitions
- Restrictive areas
- Runner-to-runner differences
AFM can help refine these surfaces.
How AFM Porting Works
A semi-solid abrasive media is pushed through the internal passage under hydraulic pressure.
Unlike a rigid porting tool, the media adapts continuously to the shape of the runner.
As it flows, abrasive particles remove controlled amounts of material from the internal surfaces.
The process can be adjusted through abrasive size, concentration, polymer characteristics, pressure, tooling, and cycle count.
Potential Intake Flow Gains
Extrude Hone AFM's Dallas automotive material states that intake-manifold AFM can increase fuel and air flow by up to approximately 25 percent in suitable applications.Improved airflow may help support:
- Increased volumetric efficiency
- Better cylinder filling
- Increased horsepower
- Improved torque
- Improved combustion efficiency
Final results depend on the entire engine.
AFM does not guarantee a particular horsepower increase.
DFW Performance and Diesel Applications
Dallas-Fort Worth has a major automotive market that includes performance street vehicles, diesel trucks, racing, restoration, off-road applications, custom fabrication, and specialty engine work.
Intake manifold porting may be particularly relevant for:
- Turbocharged engines
- Diesel engines
- Racing applications
- Performance trucks
- Classic or muscle cars
- Custom intake systems
AFM may also be useful for manufacturers processing multiple similar manifolds.
AFM vs. Hand Porting
Hand porting depends heavily on physical access and operator skill.
Long or enclosed runners may leave sections beyond the reach of a conventional grinder.
AFM avoids this problem by moving the abrasive through the passage.
That can create a more uniform internal finish and reduce the risk of localized irregularities caused by inconsistent tool access.
Material-Specific Processing
Intake manifolds may be aluminum, cast iron, or another suitable metal.
Extrude Hone AFM adjusts the abrasive formulation for the workpiece.Pressure, tooling, and number of cycles are also selected according to geometry and the desired amount of material removal.
Repeatable Results
Once a process has been developed, Extrude Hone AFM can reproduce the same tool, media, grit, and pressure conditions on similar components.
This can help with consistency in manufacturing or matched performance applications.
Call (562) 531-2976 to discuss intake manifold porting for Dallas, TX.
FAQs
Can AFM be used on diesel intake manifolds?
Potentially, yes. Diesel applications are among Extrude Hone AFM's automotive specialties.
