Abstract: A marine engine has a crankshaft that rotates about a crankshaft axis; a crankcase supporting the crankshaft, the crankcase being made primarily of a first material; and a cover on the crankcase. The cover includes a heat exchanger having an inner plate facing an interior of the crankcase, and the inner plate is located such that rotation of the crankshaft causes lubricant in the crankcase to impinge upon the inner plate. The cover also includes a frame holding the heat exchanger and isolating the heat exchanger from direct contact with the crankcase. At least a portion of the frame is made of a second material that is more compliant than the first material.

Abstract: A method of heat treating high pressure die cast objects using pressure is disclosed. A high pressure die cast object is obtained and solution heat treated to above 700° F. for at least 2 hours at pressures between 0.5 and 35 KSI or at any pressure or range of pressures therebetween. This method of solution heat treatment with pressure reduces and/or eliminates blistered defects on the high pressure die cast object. The method of heat treating by solution heat treatment with pressure also allows an increase of yield strength and corresponding weight reduction upon redesign or substantially larger safety factors for the cast object.

Abstract: A method of heat treating high pressure die cast objects using pressure is disclosed. A high pressure die cast object is obtained and solution heat treated to above 700° F. for at least 2 hours at pressures between 0.5 and 35 KSI or at any pressure or range of pressures therebetween. This method of solution heat treatment with pressure reduces and/or eliminates blistered defects on the high pressure die cast object. The method of heat treating by solution heat treatment with pressure also allows an increase of yield strength and corresponding weight reduction upon redesign or substantially larger safety factors for the cast object.

Abstract: A corrosion inhibiting system is provided with the ability to allow both primary and secondary portions of the circuit to be used in the alternative without having the primary and secondary systems interfere with each other by operating at the same time. By incorporating a continuity controller, such as a switch or a diode to selectively disconnect the sacrificial anode from the circuit, the primary and secondary systems can both be provided on a marine vessel, but used independently from each other. In that way, the primary and secondary corrosion inhibiting systems are prevented from interfering with each other during normal operation.

Abstract: An electrically conductive surface of a submerged object comprises a polymer matrix, such as a resin, with a plurality of electrically conductive nanoparticles suspended within the polymer. The nanoparticles are preferably smaller than 100 nanometers in their minimum dimension. In addition, large electrically conductive particles can be suspended in the polymer. The larger particles are typically greater than 300 nanometers in minimum dimension. The larger particles can comprise carbon powder or fibers. The electrically conductive nanoparticles, which can be nanotubes or ferrules, for example, and the larger particles, which can be carbon powder or fibers, are suspended homogeneously within the polymer matrix for best results and most uniform electrical conduction through the thickness of the composite layer.

Abstract: Antifouling materials are used to provide first and second layers or coatings on a submersible object. The first and second layers are visually distinct from each other, such as being made of two distinct colors, so that the ablation of an outer layer will be evident when an inner layer is exposed to show a different color in the regions of ablation. The materials for the first and second layers can be chemically active to cause the antifouling nature of the materials or can be electrically conductive to permit their use in the creation of either chlorine bubbles on the wetted surface or a change in ionic characteristic of water in contact with the wetted surface.

Abstract: A marine propulsion system drive unit is provided with a polymer layer to protect its outer surface from abrasion and corrosion. The polymer layer is injection molded around the outer surface of a metallic gear case structure or drive shaft housing to provide a coat which is approximately 3 millimeters thick and which will resist scratching and corrosion. The polymer layer can be a glass filled polymer or a carbon filled polymer. An adhesion promoter can be used to enhance the bonding and intimate contact between the inner surface of the polymer layer and the outer surface of the metallic gear case structure or drive shaft housing.

Abstract: A ceramic conductor is supported by an electrically insulative support member for attachment directly to a marine propulsion drive and for use as either an anode or electrode in a corrosion prevention system. The ceramic conductor is received within a depression formed in a surface of the electrically insulative support member and the exposed surface of the ceramic conductor can be offset from or coplanar with an exposed surface of the electrically insulative support member. The ceramic conductor can comprise oxides of iridium, tantalum and titanium that are formed as a coating on a titanium substrate.

Abstract: A marine fouling inhibiting system comprises first and second conductors which are made of a polymer matrix, such as vinyl ester, and a suspended conductor, such as graphite powder or particles. This type of conductive material is formed to provide two sections of a boat hull so that a source of electrical current can be used to reversibly cause an electric current to flow to and from the conductive coatings. The conductive coatings are electrically insulated from each other in order to force the formation of an electrical circuit which includes the two conductive coatings, the source of electrical current, and the water in which the boat hull is disposed. This results in the creation of chlorine bubbles on the conductive surfaces. Chlorine bubbles on the boat hull surfaces discourage the formation of marine growth, such as barnacles.

Abstract: An engine is made by providing a layer of material between the outer surface of a cylinder liner and the inner surface of the cylinder opening within an engine block. The material can be a polymer or a ceramic. Polyether ether ketone or polyethylene terephthalate can be a polymer used for these purposes. Zirconia or yttria can be ceramic used for these purposes. An electro-deposited paint can serve as the layer of thermally insulative material.

Abstract: An anode for a cathodic protection system comprises a base portion or support structure which is shaped to receive a conductive element, or insert, within a cavity of the support structure. The conductive element is made of a polymer material, such as vinyl ester, with a conductive filler, such as graphite powder. The base is attachable to a marine vessel or other submersible component that is being protected by a cathodic protection system. The anode allows the use of a relatively inexpensive resin material with a graphite filler in place of a much more expensive platinum coated titanium element.

Abstract: A multilayered submersible structure has an outer coating that is disposed in contact with water in which the structure is submerged, a current distribution layer or charge distribution layer, an electrical conductor connectable in electrical communication to a source of electrical power, and a support structure. By selectively energizing the current distribution layer, or charge distribution layer, chemical and ionic changes can be caused in the water immediately adjacent the outer coating or layer to inhibit the growth of marine organisms on the outer surface of the submersible structure.

Abstract: A method of cleaning and of heat treating lost foam castings utilizing a heated, fluidized sand bed is disclosed. The fluidized action of the sand, the movement of the casting through the sand and the heat of the bed, combine to remove residue coating resulting from the lost foam casting process from the casting.

Abstract: Poppets for fuel injectors are provided with an improved sealing surface by making the poppet from a softer material than is known in the prior art. Instead of providing a Rockwell C hardness value of 50 or greater, as is known to those skilled in the art of poppet manufacture, the improved poppet is made of a softer material that allows the valve head of the poppet to wear in such a way that its shape conforms more accurately with a valve seat of the nozzle of a fuel injector. This also provides the beneficial result of improved salt water corrosion resistance. By using a softer metal to make the poppet, the improved sealing characteristic improves fuel efficiency of the engine and reduces emissions of undesirable compounds.