Brad,
Technology doesn't matter. Humans are STILL involved. Humans are prone to error. Take the Duramax. Fantastic block and bottom end. They also have aluminum heads.
The heads are not the problem, other than the normal aluminum head flaws (i.e. work hardening). The problem is the engineers didn't require an MLS head gasket. As a result,
the owners that try to use "performance" products (i.e. tuners, bigger injectors, bigger turbos) blow head gaskets out because the standard head gaskets can't handle the higher cylinder pressures that "performance" products produce. Additionally, I've seen some Duramax blocks with deck surfaces so rough you could catch a fingernail in it. As a rule, you machine an iron block using aluminum head MUCH smoother than if you were using iron heads (Ra vs. Rz).
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“It takes considerable knowledge just to realize the extent of your own ignorance.”
Dr. Thomas Sowell
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