Abstract: A composite rotor for caliper disc brakes and the like includes an outer friction portion having two ring sections, with a plurality of supports extending therebetween to fixedly interconnect the ring sections in a mutually parallel, spaced apart relationship defining a cavity therebetween. The ring sections have opposite friction surfaces which interface with associated friction members. The rotor also includes an inner hub portion having a central mounting section which mounts the same on a drive member, and a peripheral section cast into the cavity of the outer friction portion to integrally interconnect the inner hub and outer friction portions of the rotor with primarily mechanical bonds formed at an unfused interface.

Abstract: A method of manufacturing a cylinder block comprising one or more cylinders, the or each cylinder being adapted to receive a piston therein, the method comprising making a cylinder liner by squeeze casting, in an aluminium-silicon alloy produced from a melt consisting essentially of the following composition by weight: Silicon 14% to 16%; Copper 1.9% to 2.2%; Nickel 1.0% to 1.4%; Magnesium 0.4% to 0.55%; Iron 0.6% to 1.0%; Manganese 0.3% to 0.6%; Silicon Modifier 0.02% to 0.1%, with the balance being aluminium and any avoidable impurities, the cylinder liner having an essentially eutectic microstructure containing not more than 10% primary alpha-aluminium dendrites and being substantially free from intermetallic particles exceeding 10 .mu. in diameter, placing the cylinder block in a mold and casting therearound an aluminium alloy to provide a main cylinder block body with the cylinder liner entrapped therein.

Abstract: This invention relates to heat cured binder systems comprising as separate Parts: Part I comprising (a) a soluble source of silica, (b) an alcohol, and preferably (c) a surfactant; and Part II comprising an alkali aluminate. The binder systems are mixed with a refractory to form a refractory mix. The resulting refractory mix is shaped and heated at an elevated temperature to form a cured refractory shape, particularly a preform. Heat is applied by warm air, baking in an oven, microwave, or preferably by hot-box equipment.

Abstract: A one-piece cast metal heat-exchanging forming tool is prepared using an expendable porous preform that is cast in place within a cast metal forming tool. The expendable preform is thereafter extracted to leave behind a network of inter-connected pores and passages within the body of the tool through which a heat transferring fluid may be circulated to transfer heat to or from a substantially non-porous contoured shaping surface of the tool. Fluid distribution/collection lines and vacuum lines may be incorporated in the tool during casting.

Abstract: A laminate molding method of fabricating a desired shape consisting of laminate layers having a first type layer in a completely solidified state, the method includes a first step of forming a second type layer on the first type layer, the first type layer having a viscosity larger than the second type layer, a second step of forming a slot groove in the second layer, the second type layer having first and second regions, a third step of printing a releaser on a predetermined region of the second type layer, a fourth step of forming a third type layer on the second type layer or on the first type layer, the second type having a viscosity larger than the third type layer, a fifth step of solidifying the third type layer to form the first type layer, and a sixth step of repeating the first, second, third, fourth, and fifth steps as desired.

Abstract: A method for repairing a blade tip of a turbine blade of a gas turbine engine. The method is particularly directed to replacing the squealer tip (14) of a directionally solidified (DS) or single crystal (SX) turbine blade (10), and can be carried out using a brazing or welding technique. The method generally entails the step of machining the tip (14) to remove any damaged, worn, oxidized or eroded portions thereof sustained by the blade (10) during engine operation. A DS or SX superalloy replacement tip (18) is then placed on the surface generated by the machining operation. If a brazing operation is used, a brazing alloy composition (16) is first applied to the blade tip or replacement tip (18) prior to placement of the replacement tip (18).

Abstract: A male mold having a first cavity and a female mold with a second cavity are provided, the first cavity and the second cavity having a contour complimentary to that of a golf club head, a bottom wall defining one of the first cavity and the second cavity having a recess defined therein. An insert piece is inserted into the recess. Molten metal is poured into the first cavity and the second cavity to form the golf club head in which the insert piece is integrally formed with the golf club head.

Abstract: A method for fabricating a mold by providing a matrix having a shape to be molded, and spraying molten metal from a spray gun. The spray gun is moved so that the spray gun makes successive passes over the surface of the matrix in a movement direction, shifts in a step direction transverse to the movement direction between passes and turns between passes so that during at least some successive passes metal is deposited from two spray directions in a crisscross pattern. Metal is deposited on the matrix, forming a shell which is removed from the matrix and used as a mold.

Abstract: A structural fiber reinforced ceramic matrix composite material adapted for high temperature brake use is disclosed as used for the entirety of components of a brake system and as brake pads which can be used in the normal manner for brake pads. Also disclosed is a method of integrally molding the brake pads to the surfaces of metal brake parts.

Abstract: A stamped, steel insert for use in metal die cast articles. The insert includes first and second interconnected stamped steel insert halves spaced from one another at certain locations to define a void. Openings communicating with the void extend through each insert half to facilitate material flow and to improve interlock of the insert and die cast material. The edges of the insert lie below the surface of the casting to avoid bimetallic machining. The insert halves cooperate to define a pair of elongated passages, which are bored following die casting to form fastener holes. At least one of the passages has an elongated cross section to allow for expansion and contraction of the insert during casting.

Abstract: The present invention relates to a process for producing a Mg-based composite material by using Mg or a Mg alloy as the matrix and utilizing a spontaneous infiltration phenomenon. This process comprises the step of bringing a powder mixture composed of a reinforcing agent and a infiltration agent into contact with a molten matrix metal comprising Mg or a Mg alloy, so as to cause the molten matrix metal to infiltrate into the powder mixture. The present invention also relates to a process for producing a Mg-based composite material which comprises the steps of forming a preform composed of a reinforcing agent and a infiltration agent and causing a molten matrix metal comprising Mg or a Mg alloy to infiltrate into the preform.

Abstract: A preform of reinforcement material is infiltrated with fusible metal without preceding vacuum treatment of the preform through gas pressure application solely. The infiltrated preform is allowed to solidify under pressure.

Abstract: An extension is formed directly on the end of an article by dipping the end into a molten bath of an alloy, followed by withdrawal of the end at a rate sufficient to form the extension. Extensions formed have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension onto the microstructure of the article. The method establishes a temperature gradient within the article that may be controlled by heating and/or cooling the article during the practice of the method.

Abstract: A method of fabricating MMCs having high thermal conductivity coupled with coefficient of thermal expansion (CTE) values which approximates the CTE of ceramics and semi-conductor materials typically used in electronic packaging. The method comprises preparing a formed agglomeration of powder particles (preform); partially sintering the preform; placing the partially sintered preform into a forming chamber; infiltrating the preform with liquid-phase metal; and allowing the liquid-phase metal to solidify and form an MMC around and through the preform. In a preferred embodiment, the preform is constructed from silicon carbide, and the metal matrix is an aluminum-silicon alloy.

Abstract: A iron-based material such as cast iron is made by a process wherein filler particles are added to an iron base metal, as the base metal is poured into the mold. Pieces containing ceramic filler particles held together by a binder can be disposed in the mold prior to pouring molten iron base metal therein. Molten iron base metal is then poured into the mold so that the molten base metal contacts the pieces, gradually dissolving the filler. The filler becomes distributed throughout the molten base metal within the mold. Upon cooling, the base metal has the filler distributed therein, resulting in a iron-based material. The resulting material is particularly useful for making vehicle parts normally made of cast iron or steel.

Abstract: Method for producing metal matrix composites. The method includes the steps of placing a substantially liquid metal in the vicinity of a reinforcement material and in the vicinity of the source of a transient magnetic field sufficient to produce an electromagnetic body force within the metal. The magnetic field is activated thereby propelling the substantially liquid metal into the reinforcement material thereby producing metal matrix composites.

Abstract: A replaceable bit for a circular saw is provided with a cutting portion of hard metal alloy by machining off the original cutting portion, supporting the remaining base metal portion such that a predetermined selected part extends into a chill mold, melting the surface of the selected part using a plasma arc welding torch, feeding a rod of the hard alloy into the plasma jet of the torch such that melted material from the rod drips into the mold cavity to fill it, the melted alloy mixing with the melted surface of the selected part of the remaining base metal portion in a transition zone, allowing the melted mass of hard alloy to cool and harden into a dome shape in the mold cavity, removing the bit from the mold cavity, and grinding the flank, face and back regions of the new cutting portion to selected final dimensions. Apparatus suitable for performing the process is disclosed.

Abstract: A method and apparatus for the continuous casting of composite metal members wherein molten metal is directly cast between two spaced generally parallel metal strips to form a composite member having enhanced surface qualities, formability, and strength. The method comprises feeding at least two strips of metal into a cooled mold system while pouring a molten stream of metal therebetween and forming the composite member by cooling in a cooled mold system until the composite is solidified as the exit point removing the composite from the cooled mold system and rolling the cooled composite to obtain a desired final thickness. Multiple strip and thin coating methods and apparatus are also disclosed.

Abstract: A manufacturing process of a golf club head includes the following steps: (a) Construct a hollow golf club head frame which at least two opposite supporting pins protruding outwardly from an outer perimeter thereof. (b) Position the hollow golf club head frame within a precision mold which has an internal molding cavity, wherein the internal molding cavity of the mold has at least two opposite pin slots to fittingly receive the two respective supporting pins of the hollow golf club head frame for defining an uniform intermediate gap between the outer perimeter of the hollow golf club head frame and an inner wall of the mold. (c) Fill out the intermediate gap between the mold and the hollow golf club head frame with a melted metal or alloy in order to form a rigid outer shell to uniformly conceal the hollow golf club head frame.

Abstract: Metal matrix composites are manufactured in a vacuum die casting machine. Solid aggregate material is placed in a die, the die is evacuated, and molten metal is driven by a piston to infiltrate the solid aggregate material where it subsequently solidifies to form a metal matrix composite.

Abstract: An extension is formed directly on an article by casting a compatible material into a ceramic mold that is attached on an end of the article, followed by cooling of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is utilized over the end of the article, with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on the mandrel, or preformed and attached to the subject article over the mandrel. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method.

Abstract: An invention is disclosed in which a mechanical hydraulic component includes fluid-bearing passageways. The fluid-bearing passageways are defined by a pre-formed tubing cluster which resides within a block which is cast around the tubing cluster in order to define a solid body which is fuse-bonded to the tubing cluster. The present mechanical body is formed by providing hollow tubing which is bent to provide a tube member having a desired configuration. A number of tube members are secured in order to provide a tubing cluster which defines the preformed fluid-bearing passageways. After that, a castable material is cast around the tubing cluster so as to produce a solid block with the tubing cluster embedded therein. The block and tubing cluster are formed of predetermined materials which result in chemical infiltration in order to produce a low-porosity fusion bond.

Abstract: Thin walled metal alloy receptacles are filled with a filler material. If granular, the filler material is solidified in the receptacles. The receptacles are inserted in a bit mold with their open ends abutting against preformed cutter locations in the bit mold. The mold is filled with a steel or tungsten carbide powder and a binder and exposed to temperatures sufficient to cause the binder to infiltrate the steel or tungsten carbide as well as infiltrate the receptacle outer surfaces, metallurgically bonding the receptacles to the binder. The mold is then removed, revealing a bit body with the bonded filled receptacles. The filler material is removed from the receptacles PCD cutters are inserted in the receptacles and are brazed using conventional brazing techniques.

Abstract: The present invention is directed to a process for fabricating ceramic-metal composites having continuous ceramic and metal phases. The process includes the steps of contacting a porous ceramic matrix material with a molten metal whereby capillary action pulls the metal into the ceramic matrix to substantially fill the void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.

Abstract: An apparatus for gripping and handling a casting core of the type used in the casting of metallic products and the like. The gripping apparatus includes a pair of gripping jaws which are adapted to enter an opening in the casting core and then be expanded to grip the inside of the opening with a predetermined or adjustable contact pressure. The jaws are also preferably adapted to the contour of the inside of the opening in a form-fitting manner, so as to avoid damage to the core.

Abstract: The stroke of the shot sleeve plunger is set at a high-volume setting corresponding to the volume of the die. Pre-production articles without an insert are cast within the die. The stroke of the shot sleeve plunger is set at a low-volume setting corresponding to the volume of the die minus the volume of the insert, and production articles each having an insert are cast within the die.

Abstract: The present invention relates generally to a new mold transfer apparatus and method. More particularly, the invention encompasses an apparatus that is used to form metallic interconnections, such as, for example, solder connections, such as, solder balls or solder columns, using a mold that is already filled with transferable metallic material. However, these metallic interconnections in a mold could also be used to form other structures, such as, for example, heat sinks with fins, etc.

Abstract: The present invention relates to a metal wood golf club head comprising a metal outer husk with a hollow inside portion and foaming metal or foaming carbon material compounded with carbon fibers arranged in the hollow inside portion and a metal wood golf club with this club head, and a method for producing the club head and the golf club by casting with said foaming metal or said foaming carbon material compounded with carbon fibers as a core which is rough-cut by machine to leave the portion to be kept in cutting and then is formed by a mold and covered with metal sheet.

Abstract: A reinforcing phase comprising fly ash is combined with an aqueous medium comprising a binder to produce a slurry. The slurry is then dried to produce a preform of the reinforcing phase. Molten metal is then introduced into the preform, resulting in a metal matrix composites. The reinforcing phase of the subject composites may be present in excess of 50%.

Abstract: A method of manufacturing a vehicle steering wheel metal core unit is provided. The core unit includes a tubular boss member 24 defining a tapered portion at the lower inner peripheral surface thereof, a groove 29 at the lower end of the inner peripheral surface thereof, and a compression-deformable annular projection 30 at the bottom surface thereof. The method includes setting the boss member in die casting mold 17 and closing the mold such that the molding surfaces 18a, 19a thereof are brought into pressure contact with the upper end surface 24a and the lower end surface 24b of the boss member, respectively, thereby plastically deforming the annular projection 30. Thereafter, die casting metal is injected into the mold around the boss member 24. With this method, the steering wheel metal core unit can be manufactured without the generation of fins and deformation of a tapered portion adapted to be coupled to the steering wheel shaft. Thus, manufacturing man-hours and cost can be reduced.

Abstract: An inner bearing is disposed in a cast mold formed by a punch and a die. A molten metal is poured into the die. Pressure is then applied to the molten metal. The socket plate is then knocked out by means of a pin member which passes into the mold to dislodge the socket plate.

Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known "lost-wax" method of manufacturing jewelry.

Abstract: An exhaust manifold for an engine is made of all fiber reinforced ceramic matrix composite material so as to be light weight and high temperature resistant.

Abstract: A preformed fiber reinforced metal matrix composite reinforcement insert is clad or covered with a material that is effective to avoid the adverse reactions between the insert/melt and any exposed insert fibers/matrix. The clad insert is suspended in the mold cavity and a melt is introduced into the mold cavity about the clad insert. The melt is solidified about the clad insert to provide a casting of the solidified melt having the clad insert disposed therein to reinforce the casting.

Abstract: An extension is formed directly on an article by dipping a portion or end of the article having an attached integral mandrel into a molten bath of a compatible alloy, followed by withdrawal of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is utilized over the dipped end of the article and the integral mandrel with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on the mandrel, or preformed and attached to the subject article over the mandrel. The integral mandrel is melted within the mold by dipping the mandrel into the molten alloy. The mandrel acts as a buffer between the molten material and the article while permitting melting of the article end and solidification of the integral extension. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article.

Abstract: An extension is formed directly on an article by melting a compatible alloy preform within a ceramic mold, followed by cooling of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is attached on the end of the article with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on a removable mandrel, or preformed and attached to the subject article. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method.

Abstract: An extension is formed directly on an article by melting a portion or end of the article having an attached integral mandrel within a ceramic mold, followed by cooling of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold is attached on the end of the article over the integral mandrel with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ on the mandrel, or preformed and attached to the subject article over the mandrel. Extensions formed by the method of this invention have a microstructure that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method.

Abstract: A method for producing an aluminum alloy composite material comprises disposing in a mold, in sequence from bottom to top, an infiltration enhancer containing Mg, a preform and an aluminum matrix alloy ingot, and then inserting the mold into an atmospheric furnace. The interior of the atmospheric furnace is then turned into an argon atmosphere. Thereafter, the internal temperature of the furnace is raised to a first predetermined temperature which is maintained for a given period of time so that the infiltration enhancer sublimates to permit the Mg component thereof to infiltrate into the preform. The atmosphere inside the furnace is then turned from the argon atmosphere into a nitrogen atmosphere.

Abstract: A cast abrasion resistant hollow ball is formed with a hollow ceramic core that generates no gas during the casting operation. Solid ceramic bars or supports hold the hollow ceramic core in a fixed location at the center of the cast ball during the casting process. There are no open holes or openings in the ceramic supports due to the fact that the hollow ceramic sphere is composed of an inert refractory material which eliminates any gases being generated during the pouring and solidification of the liquid metal in the casting process.

Abstract: A method of forming a metal matrix composite. The method comprises the steps of surrounding at least one insert with reinforcement material. Next, there is the step of orienting the insert and reinforcement material within a mold. Then, there is the step of infiltrating the mold with liquid metal such that the reinforcement material around the insert is infiltrated. A package comprising a metal matrix composite formed of reinforcement material infiltrated with metal. The package also comprises an insert supported in the reinforcement material by the metal. An electronic package comprising a first wall and a second wall integrally connected and extending in a continuous manner from the first wall. The first wall and second wall are a metal matrix composite formed of reinforcement material infiltrated with metal. The metal extends continuously from the first wall to the second wall. Additionally, there is an insert disposed in the reinforcement material and supported by the metal.

Abstract: The present invention describes a component with an in-situ formed insulator and a method of forming a component of the same. The method includes the step of orienting an insulator in a mold. Then, there is the step of introducing molten material, such as metal into the mold about the insulator to form a component having a cast-in electrical feed-through. Preferably, the feed-through is hermetically sealed within the component. In one embodiment, the insulator has at least one hole and the introducing step includes the step of filling the mold with molten metal to bond the metal to the insulator and to fill the hole with metal. Preferably, after the introducing step, there is the step of removing any skin of metal between metal within the hole and metal outside of the insulator. After the removing step, there can be the steps of drilling a hole into the metal within the insulator and inserting a conductor into the hole. The conductor can be brazed or cemented to the metal within the insulator.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel products produced by the method. Particularly, a permeable mass of filler material or a preform is provided which has included therein at least some matrix metal powder. Moreover, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or preform, at least at some point during the process, which permits molten matrix metal, upon contact with the filler material or preform, to spontaneously infiltrate the filler material or preform. The presence of powdered matrix metal in the preform or filler material reduces the relative volume fraction of filler material to matrix metal.

Abstract: A method of forming a breakage resistant, erosion resistant ceramic liner for a part comprising the steps of, forming a liner of a ceramic material containing pores; filling the pores with a pre-ceramic polymer resin; and, firing the liner saturated with a pre-ceramic polymer resin at a temperature and for a time which converts the resin into a ceramic within the pores. The liner can be mechanically attached, adhesively bonded or, a metal part can be cast onto the liner by placing the liner within the metal casting mold for the part as a sidewall or integral element thereof. The invention also includes method for producing parts and liners of fiber reinforced ceramic matrix composite by a resin transfer molding process or the like wherein fiber preforms are saturated with liquid pre-ceramic polymer resin. The preforms are then polymerized in a mold, the part removed from the mold, and then fired to transform the polymer to ceramic. The process can also be employed to form hollow parts such as manifolds.

Abstract: A generally annular rotor insert is formed by casting a metal matrix composite. The rotor insert includes a pair of brake friction plates which are disposed in mutually spaced apart relationship. The brake friction plates include inner surfaces and generally parallel outer surfaces. At least one of the inner surfaces of the brake friction plates is provided with a plurality of spacing elements for engagement with the inner surface of the other one of the brake friction plates for maintaining the plates in predetermined spaced apart relationship. The rotor insert is placed in a rotor mold. A hat-shaped rotor body is cast in the rotor mold whereby the spacing elements are effective to maintain the plates in a predetermined spaced apart relationship.

Abstract: A method and apparatus for the continuous casting of composite metal members wherein molten metal is directly cast between two spaced generally parallel metal strips to form a composite member having enhanced surface qualities, formability, and strength. The method comprises feeding at least two strips of metal into a cooled mold system while pouring a molten stream of metal therebetween and forming a composite member by cooling in the cooled mold system until the composite is solidified at the exit point, removing the composite from the cooled mold system and rolling the cooled composite to obtain a desired final thickness. Multiple strip and thin coating methods and apparatus are also disclosed.

Abstract: A casting mold includes a cavity formed therein, and an auxiliary mold projecting into the cavity. The auxiliary mold forms a concave portion in a cast product, and it exhibits a thermal expansion coefficient being more than a thermal expansion coefficient exhibited by a molten metal to be charged into the cavity. Hence, the auxiliary mold greatly expands thermally during casting, and it keeps the expanded state during the solidification of the molten metal. Accordingly, the casting mold can prevent the casting defects resulting from the shrinkage cavities from arising in the resulting cast products. All in all, the casting mold can obviate to give the auxiliary mold a tapered configuration, and it can reduce the after-casting machining allowance to be provided in the resulting concave portion.

Abstract: The golf club head comprises a head body which defines the front striking face of the club head. Disposed within the head body is a ceramic insert which defines the rear face of the club head. The head body is cast about the insert in a manner wherein the insert is partially encapsulated by the head body and rigidly captured therewithin.

Abstract: A method of and an apparatus for applying hard material to cutting tool teeth (12), especially the teeth of saw blades (10). Due to its surface tension, the molten material (56) forms a spherical segment (58) in a mold cavity (40) which is defined around a tooth (12). The molten material (56) is cooled in the mold cavity (40) and subsequently heated again until it reaches a state which is at least approximately liquid. Only then is pressure, progressing in the direction towards the tip (18) of the tooth, applied to the spherical segment (58), whereby the latter is flattened. Hereby the precision in shape and durability of the teeth (12) is improved which are made of hard material (56), first molten and subsequently solidified.

Abstract: The design and construction of past exhaust port liners with heat insulation capabilities have had to become more simple in order to reduce costs. However, less costly exhaust port liners may have inferior heat insulation capabilities. The present invention overcomes this and other problems with a means for encapsulating an insulating layer of material. The encapsulating means is composed of fiberglass cloth with the ability to withstand high temperatures. A blanket is formed when the fiberglass cloth encapsulates the insulating layer. The blanket is stitched in a quilted pattern to form a plurality of individual pockets. The blanket is wrapped around a ceramic body of a port liner. The quilted stitching pattern, due to separating the insulating layer into the plurality of individual pockets, protects the pockets individually. If damage should occur to one of the plurality of pockets, the insulating layer would remain intact within the remaining plurality of pockets.

Abstract: A cylinder barrel includes a casting having a plurality of ceramic bore liners cast in situ within the casting. The cylinder barrel is made by positioning the ceramic bore liners at predetermined locations within a casting mold and pouring a molten ferrous metal into the mold so as to envelope the bore liners.