Abstract: A bearing having improved wear resistance has a bearing material of a copper-tin-bismuth alloy which may also include phosphorus which has excellent strength, due to the solid solution of copper, tin and phosphorus (when used), attached to a steel backing shell. The material also has good lubricity as a result of the presence of the bismuth which also promotes tin mobilization and formation of a layer of tin on the bearing surface upon use of the bearing. The addition of small amounts of relatively small hard particles in the copper-tin-matrix, particularly Fe3P, MoSi2 or a mixture thereof, provides a suitable hard surface artifact to improve the wear resistance of the bearing material. The bearing includes a sintered powder compact bearing material of a copper-tin-bismuth alloy powder and a metal compound powder which is bonded to a steel backing shell, wherein the metal compound powder has an average particle size of less than 10 ?m.

Abstract: A gasket assembly having a secondary elastic sealing bead positioned radially inwardly of the primary sealing bead. The secondary sealing bead extends circumferentially about the aperture and radially inwardly of the primary sealing bead. A stopper layer is disposed adjacent at least a portion of the gasket layer and extends radially from the outboard region to the inboard edge to radially overlap the secondary sealing bead and the primary sealing bead. The secondary sealing bead has an “S-type” structure and provides increased gasket resiliency adjacent the inboard edge.

Abstract: A multi-layer gasket for establishing a seal between a first member (such as a cylinder head) and a second member (such as an engine block) is provided. The multi-layer gasket includes a pair of outer functional layers and at least one inner functional layer. Each layer has a full combustion bead that encircles an opening, and the full combustion beads of all of the layers are aligned radially with one another. Each layer also has an outer periphery, and the outer periphery of the inner layer is disposed radially between the aligned full combustion beads and the outer peripheries of the outer layers. The outer layers also include half beads adjacent their outer peripheries.

Abstract: A piston for an internal combustion engine is provided. The piston includes a pair of pin bosses formed of aluminum or an aluminum alloy spaced from one another in an axial direction. Each of the pin bosses has a generally circular opening for receiving a wrist pin. The pin bosses are formed integrally with surrounding areas of the piston, and each pin boss has a zone with increased hardness relative to the surrounding areas of the piston. The zone with increased hardness is at the inner periphery of the generally circular opening and resists deformation from forces between the piston and a wrist pin during operation of the internal combustion engine. Preferably, the zone with increased hardness has a dendritic microstructure with primary silicon crystallites dispersed throughout; are substantially free of pores and cracks; and have a Vickers Hardness Value of between 169 and 177.

Abstract: A method of manufacturing a coated piston ring includes applying a layer of an aluminum-based material to an outside surface of a ring body formed of an iron-based material, such as steel. The layer of an aluminum-based material is applied by thermal spraying. The method further includes an environmentally friendly heat treatment process causing the aluminum-based material to combine with the iron-based material of the ring body and form a wear resistant coating of aluminum iron (Al5Fe2). The heat treatment process can include heating to a temperature of about 550° C. for 20 minutes so that the wear resistant coating achieves a hardness of HV 1000.

Abstract: A cylinder head gasket with a single layer carrier member, a sealing ring for sealing around the cylinder opening, and at least one protection layer. The sealing ring has a plurality of functional layers. A protection layer is positioned on at least one side of the sealing ring, and preferably on both sides. The sealing ring and protection layers are fixedly secured to the carrier member by welding.

Abstract: The invention provides a low tension piston ring having a finished outer diameter and negligible tangential tension. The method includes the steps of machining a stock bar to an initial outer diameter slightly greater than the finished outer diameter of the piston ring, finishing the initial outer diameter of the stock bar to a rounded profile having a nominal diameter equal to the finished outer diameter, and machining the stock bar to the preferred cross-section. Dykes-type piston rings can have keystone or semi-keystone shaped cross-sections. The method continues by detaching the piston ring from the stock bar using a parting tool in response to completing all tension inducing operations including the steps recited above. The method continues with the steps of lapping the piston ring to a final longitudinal thickness and cutting the piston ring longitudinally to form a final gap.

Abstract: A hammer union seal assembly, hammer union seal and method of construction thereof is provided. The method of constructing the hammer union seal includes forming an annular rubber ring having a cylindrical inner surface and a cylindrical outer surface, with the cylindrical outer surface extending between opposite corner edges. The method further includes forming an annular steel ring. Then, recessing and bonding the annular steel ring in one of the corner edges with an outer surface of the steel ring remaining exposed.

Abstract: A gasket assembly and method of construction is provided. The assembly includes a carrier body having opposite planar surfaces with at least one media-conveying opening extending through the planar surfaces with at least one through opening spaced radially from the at least one media-conveying opening. Further, the carrier body has at least one projection formed of the material of the carrier body. The at least one projection extends from the at least one through opening outwardly from at least one of the planar surfaces. The assembly further includes an elastomeric material encapsulating the projection.

Abstract: An ultrasonic welding tool fabricated of powder metal material includes a body and a welding tip extending axially from the body to a working end. The powder metal material can be ferrous-based and admixed with additives, such as alumina, carbide, ferro-molybdenum, ferro-nickel, chrome or tribaloy. An exposed surface of the welding tip can comprise Fe3O4 oxides. The tool is compacted to the desired shape and sintered. The body can include a different second material compacted separately from the welding tip and then joined to the tip and sintered.

Abstract: An internal engine component including a data collector assembly is provided. The data collector assembly includes a sensor for sensing a condition and for generating a signal corresponding to the condition and a digital to analog converter for converting the signal to a digital signal. The data collector assembly also includes a memory for storing data, a clock and a processor. A power source is electrically connected to the sensor, the analog to digital converter, the memory, the clock and the processor. During an engine test, the processor, sensor, digital to analog converter, clock and memory are substantially the only devices that draw electricity from the power source.

Abstract: A non-contact labyrinth seal assembly includes a carrier having cylindrical outer flange with an annular leg extending inwardly therefrom. An elastomeric body is attached to the leg. The body has a first pair of seal lips extending radially inwardly in diverging relation from one another and a second pair of seal lips spaced radially outwardly from the first pair of seal lips. The second pair of seal lips includes radially outermost and a radially innermost seal lips. The radially outermost seal lip has a cylindrical inner surface and an inner surface of the radially innermost seal lip has a first portion extending substantially parallel to the cylindrical inner surface to form an annular channel and a second portion extending radially outwardly to an innermost lip free end that is radially aligned with the cylindrical inner surface to form an annular opening having a width less than a width of the channel.

Abstract: A wheel end assembly for a heavy-duty vehicle includes an axle spindle and a hub rotatably mounted on the axle spindle. A main seal extends radially between the axle spindle and the hub. The seal includes a dynamic portion that seats in a bore formed in the wheel hub, and a static portion that seats on the axle spindle. The static portion includes a rigid carrier that in turn includes a first member, and a second member that is rigidly attached to the first member. An elastomer is bonded to the carrier member and forms a first external lip. The first external lip extends generally parallel to a chamfer formed in an inboard end of the hub. The first external lip, other external features, and internal features prevent contaminants from entering the wheel end assembly, retain lubricant in the assembly, and provide a dynamic expulsion surface to expel contaminants.

Abstract: A steel piston with an oil gallery, and process for forming a steel piston oil gallery channel, which corresponds to the complex shape of the combustion bowl in the piston crown. The piston crown is made by a cast metal or powder metal forming process. The oil gallery channel is formed to the basic shape that corresponds to the shape of the walls of the combustion bowl. Machine-turning surfaces in the oil gallery channel can be machine-finished as desired. Surfaces in the oil gallery which cannot be machined with conventional turning operations, such as recesses and protrusions into the channel, are left in the original as-formed condition.

Abstract: A steel piston with an oil gallery, and process for forming a steel piston oil gallery channel, which corresponds to the complex shape of the combustion bowl in the piston crown. The oil gallery channel is first forged to the basic shape that corresponds to the shape of the walls of the combustion bowl. Machine-turning surfaces in the oil gallery channel can be machine-finished as desired. Surfaces in the oil gallery which cannot be machined with conventional turning operations, such as recesses and protrusions into the channel, are left in the original forged condition.

Abstract: A piston and method of construction is provided. The piston includes a top part fixed to a bottom part. The top part has an uppermost surface with annular inner and outer upper joining surfaces depending therefrom. The bottom part has a pair of pin bosses with pin bores aligned with one another along a pin bore axis; a pair of upwardly extending annular inner and outer lower joining surfaces and a combustion bowl wall. Inner and outer weld joints fix the inner and outer upper and lower joining surfaces to one another. An annular cooling gallery is formed laterally between the upper and lower joining surfaces. The inner weld joint joining the top part to the bottom part is located within the combustion bowl wall and configured to minimized the compression height of the piston.

Abstract: A shaft seal assembly includes a metal case having an annular leg extending radially inwardly to a free end with opposite oil and air sides of the leg facing respective oil and air sides of the seal assembly. An elastomeric material bonded to the leg forms a main body adjacent the free end and a primary seal lip radially inwardly from the main body. The primary seal lip has a sealing surface that extends between an air side end and free oil side end. The air side end is attached to an annular bridge via a first hinge and the bridge is operably attached to the main body via a second hinge. The first and second hinges each have a thickness that is less than a thickness of the bridge and the thickness of the first hinge is less than a thickness of the primary seal lip.

Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.

Abstract: A lighting system for the exterior of a vehicle that includes a housing, a sensor, a lamp assembly, and a controller. The sensor is carried by the housing and detects the presence of a hazard in a predetermined region on the ground adjacent to the vehicle. The lamp assembly is carried by the housing and has a light source for projecting light onto at least a portion of the region. The controller is coupled to the sensor and the lamp assembly. The controller has a light activation input and, upon receipt of a light activation command at the input, it controls the lamp assembly to project light from the lamp assembly of a first color or other visible characteristic when no hazard is detected by the sensor and of a second color or other visible characteristic when the hazard is detected by the sensor.