[LWJ]

What an excellent thread! I read the first 14 pages or so until I realized I had burned over an hour at work.

Here are a few quick thoughts, which may have been covered in pages 15-26.

1) BMW's nikasil failures (530 and 540 engines) are attributed to sulfer in the fuel and fuel injectors spraying on the cylinder wall. My opinion is that it is possible that a high pressure stream could erode the thin plating of the nikasil. Of course, the Bimmer guys think Alusil is the "good stuff."

2) I worked in an Aluminum factory a few years ago. We made some bicycles and a few other products with what was called "metal matrix composite." This was an aluminum alloy that had a very high ratio of silicon in it, similar to Alusil. My recollections of conversations with the metalurgist is that the silicon was part of a "solid solution."

3) As the silicon is integral to the substructure of the Aluminum, it is not inconceivable that a chemical etch could do an excellent job "honing" the cylinder, as referenced by the poster who had his washed in a BFPW. Aluminum is highly reactive. It will react to both acid and base PH solutions. The great news is that the silicon should be left in place (which is desired) and the aluminum could be microscopically etched back.

I don't know if this thread has lost its momentum, but I wanted to give a plausible explanation for the BFPW theory.

Thanks!

Larry