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 is first applied, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material 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 corona comprises a central electrode surrounded by an insulator, which is surrounded by a conductive component. The conductive component includes a shell and an intermediate part both formed of an electrically conductive material. The intermediate part is a layer of metal which brazes the insulator to the shell. An outer surface of the insulator presents a lower ledge, and the layer of metal can be applied to the insulator above the lower ledge prior to or after inserting the insulator into the shell. The conductive inner diameter is less than an insulator outer diameter directly below the lower ledge such the insulator thickness increases toward the electrode firing end. The insulator outer diameter is also typically less than the shell inner diameter so that the corona igniter can be forward-assembled.

Abstract: A piston assembly for monitoring at least one operating condition of an internal combustion engine and/or piston during use of the piston in the engine, for example during an engine test, is provided. The piston assembly includes an electronic instrumentation unit coupled to the piston for collecting data related to the operating conditions. Instead of a battery or wireless power transfer system, the piston assembly includes a thermoelectric module to provide energy to the electronic instrumentation unit. One side of the thermoelectric module is coupled to an undercrown surface of the piston, which is typically hot due its proximity to the combustion chamber. The opposite side of the thermoelectric module is cooled by a cooling fluid, such as a spray of cooling oil. The temperature flux at the thermoelectric module is converted into electrical energy and used to power the electronic instrumentation unit.

Abstract: A ferrous piston for gasoline powered engines having dimensions which achieve reduced mass and improved performance is provided. The piston crown has a thickness of less than 4 mm and includes valve pockets with an axial clearance between the valve pockets and an uppermost ring groove of less than 1.5 mm. The pin bosses have an axial thickness of less than 3.7% of a bore diameter, which is the largest outer diameter of the piston, measured between a pin bore and the crown at 1 mm from an inner face forming the pin bore. Each pin boss has a radial thickness of less than 3% of the bore diameter measured between the pin bore and a lower end of the pin boss. An undercrown surface presents a projected area of less than 45% of a total piston bore area, wherein the total piston bore area is ?BD2/4, BD being the bore diameter.

Abstract: A piston assembly, piston therefor and methods of construction are provided. The assembly includes a piston head and connecting rod operably coupled thereto via a wrist pin. The piston head has an upper crown with a combustion bowl and an undercrown surface. The lower crown includes axially aligned pin bores receiving the wrist pin. An upper wall of the lower crown has an oil inlet, an oil outlet and a concave, saddle bearing surface that bears against the wrist pin. A toroid-shaped outer cooling gallery is formed between wall portions of the upper and lower crowns, wherein the outer cooling gallery surrounds an inner cooling gallery. The connecting rod is fixed to the wrist pin for conjoint oscillation. The connecting rod has an oil passage in fluid communication with a through hole in the wrist pin to allow oil to flow therethrough into the inner cooling gallery via the oil inlet.

Abstract: A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A gasket for providing a gas and fluid tight between parts of an internal combustion engine, for example around a combustion chamber opening, is provided. The gasket includes a functional layer with a full embossment spaced from the combustion chamber opening. A stopper layer is attached to the functional layer adjacent the combustion chamber opening. After attaching the stopper layer to the functional layer, half embossments are simultaneously formed in the functional layer and the stopper layer adjacent the combustion chamber opening. The aligned half embossments are together referred to as a half-stop. The half-stop maintains the load on the stopper layer, limits compression on the full embossment, and protects the full embossment from combustion gases when the gasket is compressed between two parts of the internal combustion engine.

Abstract: A piston for an internal combustion engine and method of construction thereof are provided. The piston includes an upper crown formed at least in part by a first metal material and a thermally insulating insert. The upper crown has an upper wall forming an upper combustion surface and a ring belt region. The upper combustion surface is formed at least in part by the thermally insulating insert. The thermally insulating insert has a base surface with pores extending upwardly therein. The first metal material is infused and solidified in the pores, with the first metal material forming a first bonding surface. The piston further includes a body portion formed from a second metal material. The body portion provides pin bosses having coaxially aligned pin bores and diametrically opposite skirt portions. The body portion has a second bonding surface bonded to the first bonding surface of the first metal material.

Abstract: A galleryless piston having a reduced temperature during operation in an engine is provided. The piston includes an upper wall with an exposed undercrown surface. A ring belt and pin bosses depend from the upper wall, and a pair of skirt panels depend from the ring belt and are coupled to the pin bosses by struts. The piston includes an inner undercrown region and outer pockets extending along the undercrown surface. The inner undercrown region is surrounded by the skirt panels, the struts, and the pin bosses. Each outer pocket is surrounded by one of the pin bosses, a portion of the ring belt, and the struts adjacent the one pin boss. A plurality of holes extend through the pin bosses and/or the struts from the inner undercrown region to one of the outer pockets to convey cooling oil from the inner undercrown region to the outer pockets.

Abstract: A multilayer static gasket, stopper region containing distance layer therefore and methods of construction thereof are provided. The gasket includes at least one metal functional layer and at distance layer including a stopper region. The functional layer has a seal bead surrounding at least one passage to be sealed. The distance layer has a thickness extending between generally planar opposite sides, with each of the opposite sides of the distance layer having a plurality of protrusions extending outwardly therefrom and a plurality of depressions extending inwardly therein, wherein the protrusions and depressions form the stopper region. Each of the depressions extends into a separate protrusion, thereby forming an underside of the associated protrusion. The depressions extend into the opposite sides of the distance layer a distance that is equal to or greater than ½ of the thickness of the distance layer.

Abstract: A galleryless piston and method of construction provide a piston body forged from a single piece of material having an upper combustion surface extending around a longitudinal center axis along which the piston reciprocates for exposure to a combustion chamber of an internal combustion engine. The upper combustion surface has an asymmetric geometry relative to a center plane extending along the central longitudinal axis in generally perpendicular relation to a pin bore axis.

Abstract: An igniter assembly comprising an ignition coil assembly connected to a firing end assembly by an extension, with a valve assembly disposed in a pressure chamber of the extension, is provided. The valve assembly includes a valve stem biased toward the ignition coil assembly by a spring to seal the pressure chamber. The valve assembly is used to evacuate contents from the pressure chamber by pressing the valve stem toward the spring and allowing contents of the pressure chamber to travel through and past the valve stem and out of the pressure chamber. The valve assembly is also used to fill the pressure chamber with an insulating medium by pressing the valve stem toward the spring and allowing the insulating medium to travel through and past the valve stem and into the pressure chamber after evacuating the contents out of the pressure chamber.

Abstract: A corona igniter assembly including an ignition coil assembly, a firing end assembly, and a dielectric compliant member is provided. The dielectric compliant member is compressed between a high voltage insulator of the ignition coil assembly and a ceramic insulator of the firing end assembly. During assembly of the corona igniter assembly, the dielectric compliant member pushes air outwards and forms a hermetic seal between the high voltage insulator and the ceramic insulation. The dielectric compliant member can have a rounded upper surface, which may improve the hermetic seal. Alternatively, or in addition to the rounded surface on the dielectric compliant member, the lower surface of the high voltage insulator can be rounded to push air outwards during assembly and provide a hermetic seal.

Abstract: A multilayer gasket for establishing a gas and/or fluid-tight seal between a cylinder head and engine block of an internal combustion engine is provided. The gasket includes a pair of functional layers each presenting a full bead and a half bead. A single-piece stopper with a fold over adjacent the combustion chamber opening is disposed between the function layers. The stopper extends between a fifth edge and a sixth edge, wherein the sixth edge is disposed radially between the full beads and the half beads. The stopper can be cranked or coined in a location disposed between the fold over and the full beads. The stopper can also include a secondary fold over adjacent the sixth edge. A distance layer is optionally disposed between the stopper and one of the functional layers. The distance layer can also be cranked or coined between the fold over and the full beads.

Abstract: A method of forming an engineered material, for example a material for use in a bearing, is provided. The method includes forming a template polymer microlattice by disposing a perforated mask over a reservoir of ultra-violet (UV) curable resin in liquid form, conveying beams of light through the perforated mask and into the reservoir along paths, and transforming the liquid UV curable resin along the paths into a plurality of interconnected solid polymer fibers. The method further includes applying a metal material to the template polymer microlattice to form a microlattice of the metal material, and removing the template polymer microlattice from the metal microlattice. The method next includes disposing a low friction material in interstices of the metal microlattice, and sintering the low friction material disposed in the interstices of the metal microlattice.

Abstract: A piston galleryless piston capable achieving improved thermal efficiency, fuel consumption, and engine performance is provided. The piston includes an undercrown surface exposed from an underside of the piston, a ring belt, pin bosses, and a pair of skirt panels coupled to the pin bosses by struts. The piston includes an inner undercrown region extending along the undercrown surface and surrounded by the skirt panels, struts, and pin bosses. The piston also includes a pair of outer pockets extending along the undercrown surface and each being surrounded by a portion of the ring belt, one of the pin bosses, and the struts coupling the one pin boss to the skirt panels. Each pin boss includes an opening extending from the inner undercrown region to one of the outer pockets for conveying cooling oil. The opening is located between a pin bore of the associated pin boss and the undercrown surface.

Abstract: A galleryless piston having a reduced weight and a reduced operating temperature is provided. The piston includes an undercrown surface exposed from an underside of the piston, a ring belt, pin bosses each presenting a pin bore, and skirt panels depending from the ring belt and coupled to the pin bosses by strut. The piston further includes an inner undercrown region extending along the undercrown surface and surrounded by the skirt panels, the struts, and the pin bosses. The piston also includes outer pockets each extending along the undercrown surface and each surrounded by a portion of the ring belt, one of the pin bosses, and the struts coupling the one pin boss to the skirt panels. Cutouts are located in the pin bosses above the pin bores to increase the area of the undercrown surface and thus allow cooling oil to remove more heat from the undercrown surface.

Abstract: A power cylinder assembly for an internal combustion engine includes a cylinder wall that surrounds a cylinder bore that extends along an axis. A piston assembly is positioned in the cylinder bore, and the piston assembly has a combustion surface that divides the cylinder bore into a combustion chamber on one axial side of the combustion surface and a crank case on an opposite axial side of the combustion surface. The combustion surface is partially defined by a first upper surface of a first piece and partially defined by a second upper surface of a second piece. The second piece is moveable relative to the piston body during operation of the power cylinder assembly to change a compression ratio of the power cylinder assembly.

Abstract: A piston ring assembly for sealing a cylinder wall to a piston body is provided. The piston ring assembly includes a plurality of rings stacked in an axial direction one in abutment with another. Each ring has an inner face and an outer face. The piston ring assembly also includes a spring which substantially circumferentially surrounds the stacked rings and abuts the outer faces of the rings. The spring biases the stacked rings in a radially inward direction for sealing the inner faces of the rings against the piston body. The spring may be of a strip of material bent into a serpentine pattern when in an at rest condition to apply the biasing force against the piston body.