Abstract: Remanufacturing a used cylinder liner includes receiving a used cylinder liner having a fillet relieved of residual compressive stress via service in an engine, and compressing a material substrate of the cylinder liner forming a fatigue sensitive fillet, such that a non-uniform profile of the fillet is reshaped via plastic deformation of the material substrate. Residual compressive stress is restored to the fillet at least in part via the plastic deformation. A mask and used cylinder liner assembly for processing the used cylinder liner during remanufacturing is also disclosed.

Abstract: A repaired piston includes a crown composed of base and welding filler materials, and having an annular rim extending around a combustion bowl. A finite number of repaired defects are within the annular rim, and have a spatial distribution limited by a multidirectional spacing parameter, and a size distribution limited by a unidirectional sizing parameter.

Abstract: The disclosure relates to a piston ring removal tool and methods of using the same. One method includes disposing a tool between a first piston ring and a piston associated with the piston ring and rotating the piston, wherein the tool engages the first piston ring and separates at least a portion of the first piston ring from the piston.

Abstract: Remanufacturing a used cylinder liner includes receiving a used cylinder liner having a fillet relieved of residual compressive stress via service in an engine, and compressing a material substrate of the cylinder liner forming a fatigue sensitive fillet, such that a non-uniform profile of the fillet is reshaped via plastic deformation of the material substrate. Residual compressive stress is restored to the fillet at least in part via the plastic deformation. A mask and used cylinder liner assembly for processing the used cylinder liner during remanufacturing is also disclosed.

Abstract: A repaired piston includes a crown composed of base and welding filler materials, and having an annular rim extending around a combustion bowl. A finite number of repaired defects are within the annular rim, and have a spatial distribution limited by a multidirectional spacing parameter, and a size distribution limited by a unidirectional sizing parameter.

Abstract: A piston for an internal combustion engine includes a one-piece aluminum piston body including a piston head and a piston skirt adjoining the head. The skirt includes a taper narrowing towards the head and defining a major diameter in a first direction normal to a longitudinal piston axis, and a minor diameter in a direction normal to the first direction. The major diameter and minor diameter may have dimensions specified in Table 1, such that scuffing or scratching of the piston is prevented, particularly during engine break-in.