Abstract: A piston for an internal combustion engine which includes a crown having spiral features designed to increase swirl of combustion gases in a cylinder of the engine is provided. The spiral features can be located in a combustion surface or in a combustion bowl of the crown. The increased swirl of the combustion gases is expected to improve mixing of the air and fuel injected into the cylinder, and thus cause the fuel to burn more completely, achieve better efficiency out of the injected fuel, and reduce unburned hydrocarbons in the exhaust gas.

Abstract: A piston ring with a coated outer surface is provided. The coating is disposed on end sections of the outer surface adjacent a gap. Typically, a middle section of the outer surface located between the end sections is not coated. The coating can be formed of CrN or DLC, and the CrN coating can be applied by physical vapor deposition (PVD). The end sections of the outer surface, upon which the coating is applied, are rough. For example, the outer surface can be blasted or otherwise textured to achieve the rough surface. The rough surface retains oil and distributes stress better than a smooth surface, and thus reduces crazing and flaking of the coating.

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 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 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: An improved atomized powder metal material containing an increased amount of free graphite after heat treatment and/or sintering is provided. The powder metal material is typically a ferrous alloy and includes carbon in an amount of 1.0 wt. % to 6.5 wt. % and silicon in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal material. The powder metal material can also include various other alloying elements, for example at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

Abstract: A piston for a high temperature internal combustion engine is provided. The piston includes an upper wall, base wall, outer rib, and inner rib defining a cooling chamber therebetween, and a plurality of ring grooves formed in the outer rib. Only the second ring groove is formed with the keystone cross-section, and all of the other ring grooves are formed with the conventional rectangular cross-section. Thus, the piston can be formed with low manufacturing costs and can also provide exceptional performance when used in high temperature combustion engines, wherein the temperature at the first ring groove is greater than 280° C., and thus prevents carbon from depositing or burns off any carbon deposits, but the temperature at the second ring groove is between 200° C. and 280° C., in which case carbon deposits can form and cause the piston ring to stick.

Abstract: A corona comprises a central electrode surrounded by an insulator, which is surrounded by a conductive component. The conductive component includes a shell and an intermediate part both formed of an electrically conductive material. The intermediate part is a layer of metal which brazes the insulator to the shell. An outer surface of the insulator presents a lower ledge, and the layer of metal can be applied to the insulator above the lower ledge prior to or after inserting the insulator into the shell. The conductive inner diameter is less than an insulator outer diameter directly below the lower ledge such the insulator thickness increases toward the electrode firing end. The insulator outer diameter is also typically less than the shell inner diameter so that the corona igniter can be forward-assembled.

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 bearing including a backing formed of a steel material, a lining formed of aluminum or an aluminum alloy, and a diffusion barrier layer disposed between the backing and the lining is provided. The diffusion barrier layer is formed of nickel or a nickel alloy and has a thickness ranging from 1 micron to 100 microns. The bearing is typically formed by cladding the lining or plating the steel backing with the diffusion barrier layer, bonding the lining and the backing with the diffusion barrier layer between, heating to a temperature of at least 400° C., and forming the bearing into a shape after or before the heating step.

Abstract: A piston ring with a coated outer surface is provided. The coating is disposed on end sections of the outer surface adjacent a gap. Typically, a middle section of the outer surface located between the end sections is not coated. The coating can be formed of CrN or DLC, and the CrN coating can be applied by physical vapor deposition (PVD). The end sections of the outer surface, upon which the coating is applied, are rough. For example, the outer surface can be blasted or otherwise textured to achieve the rough surface. The rough surface retains oil and distributes stress better than a smooth surface, and thus reduces crazing and flaking of the coating.

Abstract: A piston for an internal combustion engine is provided. The piston includes an open inner cooling area in which the undercrown surface is exposed, and an annular outer cooling gallery. The piston also includes an oil outlet scoop for local cooling of the undercrown surface of the piston. The outer cooling gallery includes an oil outlet opening, and the oil outlet scoop is beneath and vertically aligned with the oil outlet opening. The oil outlet scoop includes a concave surface facing the oil outlet opening. During operation, oil exits the oil outlet opening, and the oil outlet scoop catches the exiting oil and directs the oil to the inner cooling area and the exposed undercrown surface.

Abstract: A multilayer static gasket, stopper region containing distance layer therefor and methods of construction thereof are provided. The gasket includes at least one metal functional layer and at distance layer including a stopper region. The functional layer has a seal bead surrounding at least one passage to be sealed. The distance layer has a thickness extending between generally planar opposite sides, with each of the opposite sides of the distance layer having a plurality of protrusions extending outwardly therefrom and a plurality of depressions extending inwardly therein, wherein the protrusions and depressions form the stopper region. Each of the depressions extends into a separate protrusion, thereby forming an underside of the associated protrusion. The depressions extend into the opposite sides of the distance layer a distance that is equal to or greater than ½ of the thickness of the distance layer.

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 wear resistant coated piston ring for an engine is provided. The piston ring includes a coating disposed on a ring body. The coating includes initially includes alternating first and second layers, wherein the first layers include trivalent chromium, and the second layers include nickel and phosphorous. The first layers are applied by depositing a trivalent chromium electrolyte, specifically Cr3+ electrolyte. The second layers are applied by electroless deposition. The coating is left in the as-is condition and is not heat treated before being disposed on a piston and then in an engine. The coating is naturally exposed to heat while the engine is running, and this heat causes the chromium, nickel, and phosphorous of the layers to diffuse and form a surface layer on a compound layer. The surface layer includes trivalent chromium, and the compound layer includes a ternary compound of chromium, nickel, and phosphorous.

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 corona comprises a central electrode surrounded by an insulator, which is surrounded by a conductive component. The conductive component includes a shell and an intermediate part both formed of an electrically conductive material. The intermediate part is a layer of metal which brazes the insulator to the shell. An outer surface of the insulator presents a lower ledge, and the layer of metal can be applied to the insulator above the lower ledge prior to or after inserting the insulator into the shell. The conductive inner diameter is less than an insulator outer diameter directly below the lower ledge such the insulator thickness increases toward the electrode firing end. The insulator outer diameter is also typically less than the shell inner diameter so that the corona igniter can be forward-assembled.