Abstract: A piston for an internal combustion engine has a piston head, a piston skirt, and a circumferential recess configured between the piston head and the piston skirt. The piston has a piston base body and a piston ring element. The piston base body has a crown region of a combustion bowl and the piston skirt. The piston ring element has a piston crown, a wall region of the combustion bowl, a circumferential top land, and a circumferential ring belt with ring grooves. The piston ring element has a circumferential cooling channel between the wall region of the combustion bowl and the ring belt, closed with a closure element. The piston base body and the piston ring element have a circumferential joining seam in the region of the combustion bowl, by way of which seam they are non-releasably connected with one another.

Abstract: Steel pistons used in many internal combustion engines are generally composed of a skirt and a crown. The skirt's function is to reduce the lateral and rotational movement of the piston in the cylinder while the engine is in operation. Lateral and rotational frictional forces imparted to a piston during engine operation cause the piston to scrape off the lubricating oil film present on the cylinder wall. The reduced oil film thickness increases piston and cylinder wall wear due to metal to metal contact. The subsequent metal to metal contact produces a phenomenon called scuffing. This disclosure incorporates several design modifications to the piston and results in a significant reduction of the lateral and rotational motion of the piston during engine operation. The reduction of piston motion reduces the amount of oil film removed from the cylinder wall and increases lubrication efficiency. The Increased lubrication efficiency realized reduces frictional wear power loss and scuffing.

Abstract: A piston assembly and a method of making the same. Exemplary piston assemblies may include a piston crown having a ring belt portion defining a cooling gallery, and a strut extending away from the ring belt portion to define a wrist pin bore. The piston may further include a piston skirt assembly secured to the strut. The piston skirt assembly may include two separate portions that each have a closure plate formed integrally with the portion, with the closure plate generally enclosing the cooling gallery. Exemplary methods of assembling a piston may include providing a piston crown having a ring belt portion defining a cooling gallery and a strut extending away from the ring belt portion to define a wrist pin bore. The methods may further include forming a piston skirt assembly having two portions having a closure plate integrally formed therewith, and securing the skirt to the crown.

Abstract: Exemplary pistons are disclosed, e.g., for an internal combustion engine. An exemplary piston includes a lower part and an upper part, whereby the lower part and the upper part define a circumferential closed cooling gallery. The cooling gallery may be provided with a gallery bottom. The piston may further include a circumferential bar positioned on the gallery bottom, the circumferential bar defining at least one coolant inlet and at least one coolant outlet extending through the bar.

Abstract: Exemplary connecting rods and methods of making a connecting rod are disclosed. A method of making a connecting rod may include the step of providing a connecting rod blank, where the connecting rod blank includes a crankshaft end and a piston pin end. The method may further include forming a crankshaft pin recess in the crankshaft end of the connecting rod blank and a piston pin recess in the piston pin end, and forming at least one lubrication recess in the piston pin end of the connecting rod blank. The lubrication recess and the piston pin recess may both formed concurrently.

Abstract: Exemplary power cell assemblies and methods of making the same are disclosed. An exemplary power cell assembly may include a piston crown and connecting rod. In an exemplary illustration, a power cell assembly includes a piston crown having a ringland extending circumferentially about a combustion bowl. The boss portions may each include inwardly extending shoulders defining arcuate crown running surfaces. The power cell assembly may further include a connecting rod having a shank and an upper end received in a cavity of the crown. The upper end of the connecting rod may define arcuate connecting rod running surfaces extending away from the shank. The crown running surfaces and connecting rod running surfaces generally allow the connecting rod to pivot with respect to the piston crown about an axis of rotation that extends from one of the boss portions to the other of the boss portions.

Abstract: Exemplary pistons are disclosed, e.g., for an internal combustion engine. An exemplary piston includes a lower part and an upper part, whereby the lower part and the upper part define a circumferential closed cooling gallery. The cooling gallery may be provided with a gallery bottom. The piston may further include a circumferential bar positioned on the gallery bottom, the circumferential bar defining at least one coolant inlet and at least one coolant outlet extending through the bar.

Abstract: A linking arm conveying generally linear movement from a piston into generally radial movement of a crankshaft is disclosed. The linking arm includes a shaft extending between a piston pin end and a crankshaft pin end. The piston pin end defines a piston pin bore. A piston pin bore surface is defined by the piston pin bore, where the piston pin bore includes a non-circular transverse profile having at least two curved surfaces that each include a distinct radius, where the at least two curved surfaces are positioned in different locations around a periphery of the transverse profile.

Abstract: A connecting rod having a small end and a large end, the small end including a pin bore defined by a pin bore surface. A thermal spray coating applied to at least a portion of the pin bore surface and a method of applying the thermal spray coating to the pin bore surface using a thermal spray technique.

Abstract: A piston for an internal combustion engine has a piston head, a piston skirt, and a circumferential recess configured between the piston head and the piston skirt. The piston has a piston base body and a piston ring element. The piston base body has a crown region of a combustion bowl and the piston skirt. The piston ring element has a piston crown, a wall region of the combustion bowl, a circumferential top land, and a circumferential ring belt with ring grooves. The piston ring element has a circumferential cooling channel between the wall region of the combustion bowl and the ring belt, closed with a closure element. The piston base body and the piston ring element have a circumferential joining seam in the region of the combustion bowl, by way of which seam they are non-releasably connected with one another.

Abstract: A connecting rod and methods for making the same are disclosed. A connecting rod may include a shaft extending between a piston pin end and a crankshaft pin end. The piston pin end generally defines a bore opening extending along an axis. The connecting rod further includes a bore surface formed integrally with the piston pin end and extending about an inner circumference of the bore opening. The bore surface may define a plurality of dimples that extend axially along the bore surface. The bore opening further may further include profiled surfaces adjacent opposing ends of the bore opening.

Abstract: A connecting rod and methods for making the same are disclosed. A method of making a connecting rod may include joining a first connecting rod blank and a second connecting rod blank together. The first connecting rod blank includes a first material, while the second connecting rod blank includes a second material different from the first material. The first and second connecting rod blanks have an interface between the piston pin and crankshaft ends. The method further includes narrowing a cross-section of the blanks at the interface, forming a piston pin aperture in the first connecting rod blank, and forming a crankshaft pin aperture in the second connecting rod blank. At least one of the narrowing and forming steps works a perimeter of the interface, thereby forming a generally smooth connecting rod surface about the perimeter of the interface.

Abstract: Exemplary piston assemblies and methods of making the same are disclosed. An exemplary piston assembly may include a piston crown and a piston skirt that is received in a central opening of the crown. The piston crown may include a ring belt portion defining, at least in part, a cooling gallery. The crown and skirt may each further include corresponding mating surfaces that extend about a periphery of the crown and skirt. The skirt mating surface and crown mating surface may generally be secured to each other that the crown and the skirt cooperate to form a continuous upper combustion bowl surface. The skirt and crown may cooperate to define a radially outer gap about a periphery of the piston crown.

Abstract: A piston assembly and a method of making the same. Exemplary piston assemblies may include a piston crown having a ring belt portion defining a cooling gallery, and a strut extending away from the ring belt portion to define a wrist pin bore. The piston may further include a piston skirt assembly secured to the strut. The piston skirt assembly may include two separate portions that each have a closure plate formed integrally with the portion, with the closure plate generally enclosing the cooling gallery. Exemplary methods of assembling a piston may include providing a piston crown having a ring belt portion defining a cooling gallery and a strut extending away from the ring belt portion to define a wrist pin bore. The methods may further include forming a piston skirt assembly having two portions having a closure plate integrally formed therewith, and securing the skirt to the crown.

Abstract: A connecting rod and methods for making the same are disclosed. A connecting rod may include a shaft extending between a piston pin end and a crankshaft pin end. The piston pin end generally defines a bore opening extending along an axis. The connecting rod further includes a bore surface formed integrally with the piston pin end and extending about an inner circumference of the bore opening. The bore surface may define a plurality of dimples that extend axially along the bore surface. The bore opening further may further include profiled surfaces adjacent opposing ends of the bore opening.

Abstract: A piston for an internal combustion engine is provided. The piston crown includes an interior surface that defines at least in part a cooling gallery and a cooling gallery surface within the piston. An annular surface may defines at least in part an annular passageway that allows fluid communication between an outer surface of the piston and the cooling gallery. Opposing annular surfaces may be abutted with a predetermined force, thereby limiting fluid flow from the cooling gallery to an outer surface of the piston. Further, an annular surface may extend into the cooling gallery to form a deflector along the cooling gallery surface, thereby limiting fluid flow from the cooling gallery to an outer surface of the piston.

Abstract: A linking arm conveying generally linear movement from a piston into generally radial movement of a crankshaft is disclosed. The linking arm includes a shaft extending between a piston pin end and a crankshaft pin end. The piston pin end defines a piston pin bore. A piston pin bore surface is defined by the piston pin bore, where the piston pin bore includes a non-circular transverse profile having at least two curved surfaces that each include a distinct radius, where the at least two curved surfaces are positioned in different locations around a periphery of the transverse profile.

Abstract: A connecting rod and methods of making a rod are disclosed. A method of making a connecting rod may include the step of providing a connecting rod blank, where the connecting rod blank includes a crankshaft end and a piston pin end. The method may further include forming a crankshaft pin recess in the crankshaft end of the connecting rod blank and a piston pin recess in the piston pin end, and forming at least one lubrication recess in the piston pin end of the connecting rod blank. The lubrication recess and the piston pin recess may both formed concurrently.

Abstract: A connecting rod and methods for making the same are disclosed. A method of making a connecting rod may include joining a first connecting rod blank and a second connecting rod blank together. The first connecting rod blank includes a first material, while the second connecting rod blank includes a second material different from the first material. The first and second connecting rod blanks have an interface between the piston pin and crankshaft ends. The method further includes narrowing a cross-section of the blanks at the interface, forming a piston pin aperture in the first connecting rod blank, and forming a crankshaft pin aperture in the second connecting rod blank. At least one of the narrowing and forming steps works a perimeter of the interface, thereby forming a generally smooth connecting rod surface about the perimeter of the interface.

Abstract: A piston for an internal combustion engine is provided. The piston crown includes an interior surface that defines at least in part a cooling gallery and a cooling gallery surface within the piston. An annular surface may defines at least in part an annular passageway that allows fluid communication between an outer surface of the piston and the cooling gallery. Opposing annular surfaces may be abutted with a predetermined force, thereby limiting fluid flow from the cooling gallery to an outer surface of the piston. Further, an annular surface may extend into the cooling gallery to form a deflector along the cooling gallery surface, thereby limiting fluid flow from the cooling gallery to an outer surface of the piston.