Abstract: A coated backing plate for a brake pad and method of manufacturing a brake pad having a coated backing plate, where the coating for the backing plate includes a bond layer. The bond layer includes an inboard surface, an outboard surface, a closed pore network toward the outboard surface that faces the inboard surface of the reinforcement plate, and an open pore network at the inboard surface of the bond layer. The open pore network includes a recessed topology having a plurality of craters configured to interlock a friction material of a friction pad or one or more intermediate layers, such as a transition layer and/or a thermal barrier layer.

Abstract: A piston capable of operating at a high temperature and consequently contributing to a high in-cylinder temperature, as well as reducing engine oil temperature, when used in an internal combustion engine, is provided. The piston includes an upper portion and a lower portion welded together to present a cooling gallery therebetween. The cooling gallery extends circumferentially around a center axis of the piston and is spaced the center axis. A partition is located in the cooing gallery and extends from one inner surface to another inner surface of the cooling gallery. The partition extends circumferentially around the center axis, and divides the cooling gallery into at least a first gallery portion and a second gallery portion. The partition can be formed as one piece with the upper portion or the lower portion. Alternatively, the partition can be formed as a separate piece from the upper portion and the lower portion.

Abstract: A piston ring providing improved performance during operation, including reduction in blowby gases and improved oil control, is provided. The piston ring includes an upper layer, a lower layer, and a middle layer each formed from a powder metal material. An exposed sharp first corner is present between an upper ring surface and an upper outer diameter surface, and an exposed sharp second corner is present between a lower ring surface and a lower outer diameter surface. The piston ring also comprises a coating including diamond-like carbon (DLC). The DLC coating is inlaid. Thus, the coating is disposed on the middle layer but is spaced from the upper and lower corners, so that the upper and lower corners of the piston ring are exposed.

Abstract: A system and method for detecting resonant frequency of a corona igniter concurrent with operation of the corona igniter is provided. The method includes providing a plurality of pulses of energy to the corona igniter, each having a pulse duration and spaced from one another by a deadtime duration during which no energy is provided to the corona igniter. Each pulse duration is ceased before current flowing in the corona igniter crosses zero, and each zero crossing of the current occurs during one of the deadtime durations. The next pulse of energy is provided to the corona igniter in response to the zero crossing of the current. A resonant frequency value is then obtained based on a sum of the pulse and deadtime durations of two consecutive cycles, or the time between zero crossings. The resonant frequency values become more accurate over time, and the drive frequency is adjusted accordingly.

Abstract: A heavy duty piston for an internal combustion engine comprises a thermally conductive composition filling 10 to 90 vol. % of a sealed cooling gallery. The thermally conductive composition includes bismuth and/or tin. For example, the thermally conductive composition can be a single-phase binary mixture of bismuth and tin. The thermally conductive composition has improved thermal properties, for example a melting point around 139° C., a thermal conductivity around 22 W/m·K, and a thermal diffusivity around 1.43E-5 m2/s. The thermally conductive composition is not reactive and does not include toxic or cost-prohibitive metals. During high temperature operation, as the piston reciprocates in the cylinder bore, the thermally conductive composition flows throughout the cooling gallery to dissipate heat away from the upper crown and thus improve efficiency of the engine.

Abstract: An insulator for a corona igniter, referred to as a barrier discharge ignition (BDI) device, for use in an internal combustion engine, is provided. A central electrode is disposed in a slot of the insulator and an electrode tip is spaced from a round insulator tip by insulating material. A shell formed of metal surrounds a portion of the insulator. The insulator has a thickness tapering between a shell firing surface and the insulator tip. The tapering insulator thickness is unidirectional and thus does not increase between a start of the taper and the insulator tip. A method of manufacturing an insulator for a corona igniter is also provided. Equations can be used to determine if a taper in the insulator thickness is needed to encourage corona propagation along a core nose projection of the insulator, and if so, the location and size of the taper.

Abstract: A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material can be applied first, followed by a mixture of the metal bond material and a ceramic material, optionally followed by a layer of the ceramic material. The ceramic material preferably includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A galleryless piston for an internal combustion engine is provided. The piston has a monolithic piston body including an upper wall forming an upper combustion surface with first and second portions. The first portion extends annularly along an outer periphery of the upper wall and the second portion includes a combustion bowl. The first portion can also include valve pockets formed therein to reduce weight. The upper wall has an undercrown surface directly opposite the second portion of the upper combustion surface. To enhance cooling, a center portion of the undercrown surface is concave, such that oil is channeled during reciprocation of the piston from one side to the opposite side of the piston. The concave center portion is axially offset from the surrounding area of the undercrown surface.

Abstract: An insert for a cylinder liner which is capable of trapping heat in the combustion chamber is provided. The insert extends circumferentially around a center axis and longitudinally from an upper end to a lower end. The insert includes an inner portion presenting an inner surface facing the center axis and an outer portion presenting an outer surface facing away from the center axis. The inner portion is formed of an iron-based material, such as steel, and the outer portion is formed of a material having a thermal conductivity of not greater than 3.5 W/mK, for example ceria stabilized zirconia. The inner and outer portions each present a thickness, and the thickness can form a gradient between the upper end and the lower end of the insert. For example, the thickness of the outer portion can be greater at the upper end than at the lower end of the insert.

Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.

Abstract: A steel piston with a bushing applied to pin bore surfaces by laser cladding or laser additive manufacturing is provided. The bushing is formed of metal, such as bronze, and metallurgically bonded to the steel of the piston. Thus, the bushing cannot fail by rotating relative to pin bore surfaces. The bushing has a porosity ranging from 0.05% to 5%, based on the total volume of the bushing, and a thickness ranging from 0.07 mm to 6 mm. Since the metal is applied directly to the steel by laser cladding or laser additive manufacturing, the overall size of the piston is reduced, compared to typical pistons with a separate steel backed bushing, and the possibility of bushing rotation is avoided. The bushing also provides scuffing resistance and increased unit load capacity of the pin bore.

Abstract: A wire for an ignition coil assembly and/or a corona ignition assembly is provided. The wire comprises a wire core including a copper-based material, and a coating applied to the wire core. The coating includes at least one of a carbon-based material and magnetic nanoparticles. The carbon-based material can include graphene and/or carbon nanotubes, and the magnetic nanoparticles can include graphene and iron oxide (Fe3O4). Typically, the coating includes a plurality of layers. For example, the coating can include a layer of the graphene and/or carbon nanotubes, and/or a layer of the magnetic nanoparticles. The coating can also include a layer of insulating material, such as enamel. According to another embodiment, the coating includes iron, nickel, and/or cobalt plated onto the wire core.

Abstract: A coated cylinder liner 20 comprises a wear resistant layer 22, such as a DLC coating, and a metallic adhesive layer 24, such as chromium or titanium, deposited on an inner surface 26 thereof. The layers 22, 24 each have a thickness tw, ta varying by not more than 5% along at least 70% of the length of the inner surface 26. The metallic adhesive layer 24 is deposited by sputtering a consumable metallic electrode 28 onto the inner surface 26. The sputtering can be magnetron sputtering. The consumable metallic electrode 28 can include a hollow opening 40 with orifices 50 for providing a carrier gas into the deposition chamber 52. In addition, the inner surface 26 of the cylinder liner 20 can provide the deposition chamber 52 by sealing a first opening 36 and second opening 38 of the cylinder liner 20.

Abstract: A piston for an internal combustion engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. According to one embodiment, a bond layer of a metal is applied to a combustion surface of the crown, followed by a mixed layer of metal and ceramic with a gradient structure, and then optionally a top layer of metal. The thermal barrier coating can also include a ceramic layer between the mixed layer and top layer, or as the outermost layer. The ceramic includes at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray, HVOF, or wire arc spraying. The thermal barrier coating preferably has a thickness less than 200 microns and a surface roughness Ra of not greater than 3 microns.

Abstract: A corona igniter assembly which is designed to reduce the amount of air gaps between insulating components and thus reduce electrical fields concentrated in those air gaps and the associated unwanted corona discharge. The assembly includes a high voltage center electrode surrounded by a ceramic insulator and a high voltage insulator. A dielectric compliant insulator is disposed between the ceramic insulator and the high voltage insulator. A layer of metal is applied to at least one of the insulators, for example the ceramic insulator. A compliant collet formed of a partially resistive material covers a sharp edge of the layer of metal to reduce the electric field and smooth the electric field distribution at the sharp edge of the metal layer.

Abstract: A vehicle internal combustion piston and method of construction thereof are provided. The piston includes piston body extending along a central longitudinal axis, having an upper combustion wall forming an upper combustion surface and an undercrown surface opposite the upper combustion surface. An annular ring belt region depends from the upper combustion surface, a pair of skirt panels depend from the ring belt region, and a pair of pin bosses depend from the undercrown surface to provide laterally spaced pin bores aligned along a pin bore axis for receipt of a wrist pin. The undercrown surface forms a central undercrown surface, and a portion of either an open outer cooling gallery, a sealed outer cooling gallery, or an outer galleryless region, wherein an insulating coating is applied to at least one of the portions of the undercrown surface.

Abstract: A sintered material for use in an internal combustion engine, such as a valve seat insert, is provided. The material includes a pressed base powder metal mixture and a Cu-rich phase infiltrated in pores of the base powder metal mixture. The base powder metal mixture includes at least one of Mo and W, and at least one additive, such as B, N, and/or C. The amount of the Mo and/or W is 50 wt. % to 85 wt. %, based on the total weight of the material. The at least one additive is present in a total amount of 0.2 to 25 wt. %, based on the total weight of the material, and the Cu-rich phase is present in an amount of 15 wt. % to 50 wt. %, based on the total weight of the material. The material also has a thermal conductivity of at least 70 W/mK.

Abstract: A metal static gasket and method of construction thereof is provided. The gasket includes at least one metal layer. The at least one metal layer has opposite sides with at least one through opening extending through the opposite sides configured to register with an opening to be sealed and at least one raised annular seal bead extending at least in part about the at least one through opening. At least one protrusion extends outwardly from at least one of the sides, wherein the at least one protrusion prevents complete flattening of the at least one seal bead. The at least one protrusion has a plurality of discrete layers of metal deposited on one another via an additive manufacture process, wherein the protrusion is formed having a hollow region extending therein.

Abstract: A piston for an internal combustion engine including a cooling gallery and a complex combustion surface is provided. The piston includes an upper crown member joined to a lower member, for example by hybrid induction welding. A complex combustion bowl is formed in the upper crown member by forging. The combustion bowl includes at least one protrusion, and typically a plurality of protrusions spaced from one another. After the forging step and before the joining step, portions of an undercrown surface located opposite the spaces between the protrusions are machined, and portions located directly opposite the protrusions are left as-forged. The crown member is joined to the lower member, for example by hybrid induction welding.

Abstract: A corona igniter including a hermetic combustion seal between an insulator and center electrode is provided. The combustion seal includes a metallic coating, such as a nickel-based layer applied to a layer of molybdenum-manganese, and the metallic coating is disposed on the insulator inner surface. Optionally, a shot of copper-based powder can be disposed on a head of the center electrode. The center electrode and/or the copper-based powder is then brazed to the metallic coating on the inner surface of the insulator. The process can include applying the metallic coating to the inner surface while applying a metal coating to an outer surface of the insulator. The method further includes brazing the center electrode and/or the copper-based powder to the metallic coating on the inner surface while brazing the metal coating on the outer surface to a metal shell.