How a Maserati is made: focus on light alloy foundry and engine assembly

Maserati cylinder heads, blocks and crankcase are made at the Ferrari Factory in Maranello where a special metal alloy is used to improve the mechanical characteristics of each individual component. Light alloy technology is intensively used in producing the eight cylinders Maserati’s mechanical parts and it is a critical stage in the production cycle.

An in-depth check of the metal to be employed is the first step in the production cycle. It will be severely checked to make sure it conforms to strict technical standards. Once the metal has been certified, the “core” and “shell” are prepared hence a controlled cooling process begins to prevent bubbles to be formed inside the casting. Any residual of the metal are removed and the structure’s interior is heated to be homogenized. An ageing procedure will follow through a heat treatment which guarantees durable components. Each element will ultimately undergo a final examination which includes some radioscopic sample checks.

Engines that will ultimately power the Maserati GranTurismo and Quattroporte are assembled exclusively by Factory trained personnel at Ferrari headquarter in Maranello, Italy. The personnel training period aims to familiarize them with the assembly procedures, to teach them how the engine works and how to diagnose problems. A certification is granted to each employee who completes the training stating they are ready to work on the real production process.

The production of the compact and lightweight eight cylinders 90° Maserati engine takes place in the Engine Mounting Area in the proximity of Ferrari engines’ assembly line. The process begins by preparing one of the following sub-groups: air intake manifolds, pistons, cylinder heats preparation. Once subgroups are completed, the finish lines will assembly each component where Maserati and Ferrari engines will alternate on the same work cycle. Each cycle is divided into short blocks (cylinder blocks and piston rods) and long block (where final engine assembly will occur).

The overall production system combines the advantages of the work and accuracy performed by human being with the precisions given by sophisticated machines. A special bolt tightening certification system sends the torque data to a central server, which will then compare the values with strict parameters set by the technical department. The process will move forward to the next step only if the two values exactly match. Each individual engine is then verified in the testing room, where the engines are set at 2,000 rpm for twenty minutes, at 4,500 rpm for other twenty minutes and ultimately at 6,000 rpm for thirty minutes. The last analysis involves checking the torque curve, the peak power and final emissions. Once the last phase is positively completed, the engine is ready to be sent to the Maserati Factory in Modena to be mounted in a car.

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Maserati Silicon Valley provides used and New Maserati to Silicon Valley’s affluent communities. Discover the new Maserati GranTurismo and Maserati Cost today.

Author (maseratisiliconvalley). Submitted on Wed, 11 Jan 2012 Time: 2:57 PM

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