Abstract: Method of bonding cylinder liners to cylinder bore walls, comprising: (a) inserting a cylindrical work hardenable liner into a complementary sized cylindrical bore wall of the block, with a uniform annular radial spacing therebetween of about 0.005 inch; and (b) forcing a nondeformable mandrel throughout the interior length of the cylindrical liner to uniformly circumferentially expand the radially outer surface of the liner into full annular surface-to-surface heat exchange relationship with the interior surface of the bore wall, the mandrel having a cross-sectional radius greater than the interior radius of the liner by a dimension which is at least 0.001 inch in excess of such radial spacing. Preferably, the cylindrical liner is comprised of steel having a ductility of at least 30%, a hardness of at least 35 HRB, and a wall thickness in the range of 0.050-0.250.

Abstract: A method of casting-in-place iron cylinder liners in light alloy, preferably aluminum, engine blocks is made possible by a cylinder liner insert comprising at least two generally cylindrical cylinder liners which are joined together along aligned portions of the liners in a "semi-siamese" fashion. The cylinder liners are joined at the lower ends of the liners with the upper combustion ends remaining independent and unattached. Alternately, narrow ribs can be formed at or arched above the upper ends of the liners to join and stabilize the upper ends of the liners during cylinder block casting operations, with such ribs ultimately being machined off during block finishing operations.