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CASE STUDY: PR2 RACING

ToughMet® Finishes First in Extreme Conditions

Proven successful in the toughest applications from aerospace to agriculture, ToughMet®, a copper-nickel-tin alloy system, was recently recognized by two enterprising engineers as the material of choice for use in Motocross/Off-road bikes.

In 1999, avid motorcyclists Chris Durham and Jeff Peinhardt combined their talents to form PR2 Racing. Both have technical backgrounds gained from tuning engines and suspensions for their personal equipment as well as that of friends. Over the years, PR2 Racing has evolved into a company that offers the highest level of modern technology available in the Motocross/Off-road market. The founders pride themselves in having comprehensive knowledge in:

  • mechanical engineering
  • combustion engine technology
  • precision manufacturing

Since the company was founded, PR2 Racing has equipped racers that have won countless regional, state and local championships across the country. Durham and Peinhardt strive to equip themselves and their racers with the best available engines and suspensions.

TOUGH CONDITIONS DEMAND TOUGHMET®
When experiencing galling and wear issues with titanium valves, rather than replace the valves themselves, Peinhardt looked for an alternative valve guide material. He found it with Brush Wellman's ToughMet 3 AT110 engineered alloy. ToughMet was used to replace the conventional valve guide and produced "phenomenal results." "Motocross engines experience similar abuse as Formula 1 engines. Both are 4-valve per cylinder engines, routinely operating above 10,000 RPM, and driven under extreme conditions," said Ed Curnow, Account Manager for Brush Wellman. "Because we understand the dynamics of these types of engines, we knew that PR2 Racing would realize a number of advantages by switching their valve guide material from cast steel or bronze to ToughMet."

ADVANTAGES RACE AHEAD OF COMPETITION
PR2 Racing has been using ToughMet for nearly 11/2 years. The final product, a cylinder head, is used in a single cylinder, four stroke engine that goes on a Motocross bike. "We've been able to notice a number of advantages by using ToughMet," said Peinhardt. "In addition, the material is very friendly to work with where other bronzes were quite abrasive." Advantages of ToughMet include:

  • substantially reduced wear of the titanium valve stem, as well as the valve seat
  • allowance of extremely close clearance between valve guide and valve stem
  • elimination of galling
  • extended guide life
Peinhardt continued, "We were getting about 8 hours of use with the cast steel, now we are easily getting 15 hours with ToughMet. This has doubled the life of the valve and guide because of the ToughMet lubricity in relationship with the titanium valve stem." The extended life alone is saving the company more than $500 per cylinder head per 8 hours of run time.

TOUGHMET® IMPACTS RACING INDUSTRY
With a proven track record in heavy duty mining, construction and off-highway applications, ToughMet alloy combines the strength of aerospace alloys with the low friction of leaded bronze. In applications where ToughMet has replaced traditional bearing materials, it has eliminated premature failures and extended maintenance cycles by a factor of 4 or more. These extreme applications make ToughMet perfect for the high performance racing industry. ToughMet has experienced success in engine valve guides and bearings for race cars as well as pump applications for funny cars. Other successful racing applications include thrust washers, wear plates and bushings for suspension, rocker arms, distributors, lifters, wrist pins, turbo chargers and transmissions.

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