Abstract: A friction damping cast component and method of production are disclosed. The components may be rotary, such as a cast brake rotor, or may be non-rotary, such as a cast suspension part or a cast engine block. Regardless of the type of component, a two-part vibration-damping insert having a thin metal core and a thin metal sheath is provided. The sheath fully encompasses the core in such a way that a dry sliding friction contact develops at their interfaces. The outer surface of the sheath with the metal core inside is rigidly bonded to the cast material that surrounds it during the casting process. The sheath surfaces may have a number of openings that allow a limited infiltration of molten cast iron material just inside the immediate vicinity of the sheath openings for spot rigid bonding between the surrounding cast material and the insert surfaces during casting.

Abstract: An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

Abstract: A cylinder block for an engine includes a first composite portion having a first surface adjacent to a first recess, a second composite portion having a second surface adjacent to a second recess, and a cylinder liner received by the first and second recesses and positioned between the first and second portions. The first surface is adapted to mate with the second surface along a plane extending through the cylinder liner.

Abstract: An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

Abstract: A cylinder block for an engine includes a first composite portion having a first surface adjacent to a first recess, a second composite portion having a second surface adjacent to a second recess, and a cylinder liner received by the first and second recesses and positioned between the first and second portions. The first surface is adapted to mate with the second surface along a plane extending through the cylinder liner.

Abstract: An engine is provided. The engine includes a thermal set composite cylinder block including a front engine cover attachment interface and a transmission attachment interface and a cylinder liner integrally molded with the composite cylinder block, the cylinder liner defining a portion of a boundary of a cylinder. The engine further includes a bulkhead insert extending through the thermal set composite cylinder block and is directly coupled to a cylinder head.

Abstract: An engine is provided. The engine includes a thermal set composite cylinder block including a front engine cover attachment interface and a transmission attachment interface and a cylinder liner integrally molded with the composite cylinder block, the cylinder liner defining a portion of a boundary of a cylinder. The engine further includes a bulkhead insert extending through the thermal set composite cylinder block and is directly coupled to a cylinder head.

Abstract: A plurality of inter-connected cores includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation thereto. A cylinder block mold core package (22) is assembled from the cores (14, 24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. To prevent migration, a mechanical interlock is provided between each liner (10) and its associated barrel core (18).