Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A piston (120) and method for making a piston (120) for a fuel-injected diesel engine adapted to withstand the damaging effects of fuel injection plume-induced oxidation in the regions of the piston bowl (134) and rim (130). The surfaces of the piston crown (126) targeted by the fuel injection plume (138) are first coated with a corrosion-resistant and oxidation-resistant composition applied as a slurry or by a thermal spraying technique, such as HVOF or plasma spraying. Thereafter, a high energy industrial laser beam irradiates the as-sprayed coating to increase its density, while simultaneously reforming its microstructure so as to fuse, alloy, and materially bond the coating material with the underlying steel substrate, thereby resulting in a durable protective surface for the steel piston crown (126).

Abstract: A piston (120) and method for making a piston (120) for a fuel-injected diesel engine adapted to withstand the damaging effects of fuel injection plume-induced oxidation in the regions of the piston bowl (134) and rim (130). The surfaces of the piston crown (126) targeted by the fuel injection plume (138) are first coated with a corrosion-resistant and oxidation-resistant composition applied as a slurry or by a thermal spraying technique, such as HVOF or plasma spraying. Thereafter, a high energy industrial laser beam irradiates the as-sprayed coating to increase its density, while simultaneously reforming its microstructure so as to fuse, alloy, and materially bond the coating material with the underlying steel substrate, thereby resulting in a durable protective surface for the steel piston crown (126).

Abstract: The invention provides a method for forming a tribologically enhanced surface on a work-piece. The method includes the step of combining a predetermined material operable to enhance tribological properties with a liquid to form a slurry or a solution. The method also includes the step of applying the slurry/solution to a surface of a work-piece. The method also includes the step of transforming the phase of the predetermined material with a laser after the applying step. Transforming the phase of the predetermined material generates a chemical reaction binding the tribological agent with the surface of the work-piece.

Abstract: The invention provides a method for machining a work-piece. The method includes the step of disposing a surface of a work-piece and an electrode a predetermined distance apart. The method also includes the step of directing a flow of electrolyte between the surface and the electrode. The method also includes the step of applying a voltage across the surface and the electrode to machine the work-piece to generate a current. The method also includes the step of adding a first predetermined material to the flow of electrolyte to bind to the surface of the work-piece and leave a protective layer.

Abstract: The invention provides a method for processing a ferrous work-piece. The method includes the step of coating a surface of a ferrous work-piece with a predetermined material. The method also includes the step of generating a plasma at the surface with a laser by at least partially vaporizing the predetermined material to release electrons and ions. Different materials can be selected as the coating material to promote different surface changes. For example, carbon can be selected as the coating material for improved hardness. Phosphate can be selected as the coating material for enhanced tribological properties.

Abstract: A method of depositing thin coating layers a wide variety of coating materials on a wide variety of substrate by fusing a slurry coating of the coating material onto a coating surface of the substrate by application of energy from a laser. The coating materials and substrates may include pure metals and metal alloys, ceramics, cements, polymers and composites of these materials. The method produces a fused coating layer in a predetermined pattern by the use of a reflective mask, such as a polished metal mask of a metal that is particularly adapted to reflect the wavelengths of the laser energy used to fuse the coating. The method may be implemented as an additive process to produce the fused coating layer, or alternately, it may be implemented as an additive and subtractive process.

Abstract: The subject invention provides a heat treating assembly. The heat treating assembly comprises a laser, a substrate, and a tool. The laser emits laser energy directed toward the substrate and the tool. The substrate absorbs the laser energy and produces heat energy within the substrate that alters the substrate. The tool is disposed in removable contact with the substrate to conduct the heat energy away from the substrate to limit the altering of the substrate. Preferably, the tool has a thermal conductivity greater than that of the substrate and is more preferably a copper material, a gold material, a silver material, or an aluminum material.

Abstract: A sparkplug having ground and center electrodes that include a firing tip formed from a noble metal or noble metal alloy by reflowing of a noble metal preform. The present invention also includes a method of manufacturing a metal electrode having an ignition tip for an ignition device, including forming a metal electrode having a firing tip portion; applying a noble metal preform to the firing tip portion; and reflowing the noble metal preform to form a noble metal firing tip.