Abstract: An engine block formed according to a method that includes forming an insert, coating the insert with a bond material, placing the insert within a casting mold or die, purging the casting mold or die with an inert gas, filling the casting mold or die with molten metal to encapsulate the insert, diffusion bonding the molten metal to the insert to form a diffusion bonded insert, placing the diffusion bonded insert within a cavity of a secondary casting mold or die, filling the secondary casting mold or die with molten metal to form an engine block composite casting assembly, and casting and heat treating the engine block composite casting assembly is provided. The insert can be free of serrations for mechanical coupling between the insert and the engine block.

Abstract: Systems are provided for cooling a cylinder block via bore bridge cooling passages. In one example, a cylinder block with a bore bridge positioned between a first cylinder and a second cylinder, the cylinder block also including a coolant jacket at least partially surrounding the first cylinder and the second cylinder, has at least one cooling passage positioned within the bore bridge. An inlet of the at least one cooling passage has a larger area than an outlet of the at least one cooling passage and at least a portion of the at least one cooling passage has a non-cylindrical geometry formed by a lost core.

Abstract: Systems are provided for cooling a cylinder block via bore bridge cooling passages. In one example, a cylinder block with a bore bridge positioned between a first cylinder and a second cylinder, the cylinder block also including a coolant jacket at least partially surrounding the first cylinder and the second cylinder, has at least one cooling passage positioned within the bore bridge. An inlet of the at least one cooling passage has a larger area than an outlet of the at least one cooling passage and at least a portion of the at least one cooling passage has a non-cylindrical geometry formed by a lost core.

Abstract: Methods and systems are provided for a water jacket diverter. In one example, the water jacket diverter has a continuous upper rail with a profile including curved and linear portions where the profile of the upper rail is optimized to moderate coolant flow through the water jacket. The water jacket diverter further includes at least one protrusion extending outwards from an outer face of the diverter, the at least one protrusion positioned in front of a coolant inlet.

Abstract: Methods and systems are provided for a water jacket diverter. In one example, the water jacket diverter has a continuous upper rail with a profile including curved and linear portions where the profile of the upper rail is optimized to moderate coolant flow through the water jacket. The water jacket diverter further includes at least one protrusion extending outwards from an outer face of the diverter, the at least one protrusion positioned in front of a coolant inlet.

Abstract: Systems are provided for cooling a cylinder block via bore bridge cooling passages. In one example, a system may include a cylinder block with a first cylinder and a second cylinder adjacent to the first cylinder and a bore bridge positioned between the first cylinder and the second cylinder, the cylinder block further including a coolant jacket at least partially surrounding the first cylinder and the second cylinder. The system may further include a cooling passage positioned within the bore bridge, the cooling passage including an inlet fluidly coupled to the coolant jacket and an outlet positioned at a deck face of the cylinder block, the cooling passage curving from the inlet to the outlet with a curvature greater than zero.

Abstract: An engine block formed according to a method that includes forming an insert, coating the insert with a bond material, placing the insert within a casting mold or die, purging the casting mold or die with an inert gas, filling the casting mold or die with molten metal to encapsulate the insert, diffusion bonding the molten metal to the insert to form a diffusion bonded insert, placing the diffusion bonded insert within a cavity of a secondary casting mold or die, filling the secondary casting mold or die with molten metal to form an engine block composite casting assembly, and casting and heat treating the engine block composite casting assembly is provided. The insert can be free of serrations for mechanical coupling between the insert and the engine block.

Abstract: A method of forming an assembly is provided. The method includes forming an insert, coating the insert with a bond material and placing the insert within a casting mold or die. The casting mold or die is purged with an inert gas and the casting mold or die is filled with molten metal to encapsulate the insert. The encapsulated insert is diffusion bonded to the molten metal to form a diffusion bonded insert, which is placed within a cavity of a secondary casting mold or die. The secondary casting mold or die is filled with molten metal to form a composite casting assembly. After or during the casting, the composite casting assembly is heat treated. In another method of the present disclosure, the insert includes ferrous alloys, nickel-based alloys, super alloys, and nonferrous alloys.

Abstract: A method of forming an assembly is provided. The method includes forming an insert, coating the insert with a bond material and placing the insert within a casting mold or die. The casting mold or die is purged with an inert gas and the casting mold or die is filled with molten metal to encapsulate the insert. The encapsulated insert is diffusion bonded to the molten metal to form a diffusion bonded insert, which is placed within a cavity of a secondary casting mold or die. The secondary casting mold or die is filled with molten metal to form a composite casting assembly. After or during the casting, the composite casting assembly is heat treated. In another method of the present disclosure, the insert includes ferrous alloys, nickel-based alloys, super alloys, and nonferrous alloys.