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 piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

Abstract: A piston for an internal combustion engine is provided. The piston includes a coating applied to a ferrous body portion to reduce or prevent chemical bonding of carbon deposits or coking on the body portion at temperatures ranging from 200 to 400° C. The coating includes a fluoropolymer, such as polytetrafluoroethylene, fluorosilane, fluorocarbon, fluoroplastic resin, and/or perfluoroplastic, and may be hydrocarbon or silicone based. The coating also has a thickness of 25 microns to 1 millimeter. The coating can be disposed on an undercrown surface, ring grooves, ring lands, pin bosses, and/or skirt sections of the body portion.

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 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 piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

Abstract: A piston for an internal combustion engine is provided. The piston includes a coating applied to a ferrous body portion to reduce or prevent chemical bonding of carbon deposits or coking on the body portion at temperatures ranging from 200 to 400° C. The coating includes a fluoropolymer, such as polytetrafluoroethylene, fluorosilane, fluorocarbon, fluoroplastic resin, and/or perfluoroplastic, and may be hydrocarbon or silicone based. The coating also has a thickness of 25 microns to 1 millimeter. The coating can be disposed on an undercrown surface, ring grooves, ring lands, pin bosses, and/or skirt sections of the body portion.

Abstract: A piston for an internal combustion engine is provided. The piston includes a coating applied to a ferrous body portion to reduce or prevent chemical bonding of carbon deposits or coking on the body portion at temperatures ranging from 200 to 400° C. The coating includes a fluoropolymer, such as polytetrafluoroethylene, fluorosilane, fluorocarbon, fluoroplastic resin, and/or perfluoroplastic, and may be hydrocarbon or silicone based. The coating also has a thickness of 25 microns to 1 millimeter. The coating can be disposed on an undercrown surface, ring grooves, ring lands, pin bosses, and/or skirt sections of the body portion.

Abstract: A component for an engine is provided. The component includes a thermal barrier coating applied to a body portion formed of metal, such as steel or another ferrous or iron-based material. According to one embodiment, a bond layer of a metal is applied to the body portion, 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 can be applied by thermal spray. 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 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 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: 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 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 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 steel piston with anti-coking design features is provided. The piston includes an upper crown portion and a lower crown portion forming an outer cooling gallery therebetween. The outer cooling gallery is substantially closed except for an oil inlet, oil outlet, and optional oil passage(s) to a central cooling gallery. According to one embodiment, at least one anti-coking insert is disposed in the outer cooling gallery and sized to prevent escaping through the oil inlet or the oil outlet. For example, the insert(s) can comprise a helical coil, a plurality of steel balls, coil springs, or chips formed of polymer with abrasive filler. Alternatively, an outer gallery floor to the outer cooling gallery includes a plurality of anti-coking openings disposed sequentially in decreasing spaced relation from one another, or anti-coking openings with varying lengths.

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 region, and a portion of either an open outer cooling gallery, a sealed outer cooling gallery, or an outer galleryless region. A coating including copper is applied to hot spots along the undercrown surface to mitigate the hot spots provide a more uniform temperature along the undercrown surface during operation.

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 region, and a portion of either an open outer cooling gallery, a sealed outer cooling gallery, or an outer galleryless region, wherein an insulating coating including a thermoset resin, such as a phenolic or epoxy resin, with additives is applied to at least one of the portions of the undercrown surface.

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.