Abstract: A method of flexibly manufacturing engine blocks by first bonding an extruded tube liner insert, of a given thickness (1-15 mm), to a fixed configuration block, the liner insert having been coated with an anti-friction wear-resistant coating having a controlled standard thickness, and secondly bonding an extruded tube liner insert of a different thickness (again selected from 1-15 mm) to another of the fixed configuration blocks, the second liner insert having been coated with the same type of anti-friction wear-resistant coating in essentially the same controlled standard thickness. The common sized engine block can have (i) identically shaped circular cylindrical bore walls or (ii) ovoid cylindrical bore walls with the liner insert having an interior surface shape selection varying between circular to ovoid. The block and liner insert may be both made of aluminum.

Abstract: A composition of matter for depositing a thin anti-friction film that has a coefficient of friction of 0.06 or less. The composition comprises (a) a mixture of solid lubricant particles, a thermoset resin, and a catalyst for setting the resin, and (b) an evaporative medium for carrying the mixture during deposition. A solid film lubricant system for protecting metal wear interfaces subject to high temperatures and wet lubrications, comprising an oil-attracting solid lubricant mixture with at least two elements selected from the group of graphite, MoS.sub.2 and BN; a support for the mixture to loads of at least 10 psi at temperatures of 600.degree.-800.degree. F. while being thermally stable; a thermally stable thermoset polymer matrix, the polymer having inherent hydrocarbon chemical attraction to form a tenacious oil film of the lubricating oil on the wearing surface.

Abstract: Method of making a piston ring assembly by providing a metallic (i.e. cast aluminum) piston with a crown and an annular depending side wall; machining a stepped annular groove in the side wall having a total height of at least 4 mm (preferably having a combined total height equal to the groove height less 60 microns or less); fabricating a pair of metallic (i.e. aluminum based) split annular compression rings nestable within said groove and effective to operate together as a superimposed unit to seal against both said step and groove; coating said groove and the non-mating surfaces of said rings with solid film lubricants (i.e. graphite, BN and MoS.sub.2); and inserting said pair of coated rings into said coated groove with their split ends out of superimposed alignment.

Abstract: A piston and ring assembly operative within a cylindrical bore wall to retain fluid to one side of the assembly, comprising a piston having at least one annular stepped groove in the side wall of the piston, the groove being stepped into uppermost and lowermost spaces with the uppermost space having the greatest depth; at least two split compression rings in the groove, effective to each substantially annularly engage the bore wall, the rings having mating surfaces superimposed one upon another and having their split ends out of superimposed alignment, and a solid lubricant that coats essentially all of the groove and constitutes the non-mating surfaces of the superimposed rings. Pressure of the retained fluid forces the rings together to act in unison and seal jointly against both the step and a side of the groove opposite the retained fluid.

Abstract: A solid film lubricant system for protecting metal wear interfaces subject to high temperatures and wet lubrications, comprising an oil-attracting solid lubricant mixture with at least two elements selected from the group of graphite, MoS.sub.2 and BN; a support (i.e., hard lands or hard sublayer) for the mixture to loads of at least 10 psi at temperatures of 600.degree.-800.degree. F. while being thermally stable; a thermally stable thermoset polymer matrix adhering the mixture to the support or the wear surface, the polymer having inherent hydrocarbon chemical attraction to form a tenacious oil film of the lubricating oil on the wearing surface. A method of making anti-friction coated surfaces comprising providing a light metal based cylinder surface (i.e.

Abstract: A method of making an anti-friction coating on a metal surface subject to sliding wear, including the steps of: forming an encapsulated powder having grains made of a core of solid lubricants including at least graphite and MoS.sub.2 (others may include BN, NaF, LiF, CaF.sub.2, and WS.sub.2), and a thin shell of fusable soft metal such as Ni, Co, Fe, Zn, Sn, Mg, or Cu; plasma spraying the powder onto a light metal surface, such as a cylinder bore wall of an internal combustion engine, to form a coating; and finish-smoothing the coating to a uniform thickness of about 25-175 microns. Some core particles may be hard, wear-resistant particles such as SiC, NiCrAl, FeMn, FeCrAl, FeWNiVCr, NiCrMoVW, FeCrMoWV, CoFeNiCrMoWV, NiCrMoV, and CoMoCrVW.

Abstract: An engine block having one or more anti-friction coated cylinder bore walls, comprising: a coating of grains fused to the cylinder bore wall, the grains being comprised of solid lubricant particles encapsulated within a soft metal shell, the shells being fused together to form a network with limited porosity, the solid lubricant comprising at least graphite and MoS.sub.2 ; and wet oil lubrication retained within the porosity of the coating.

Abstract: A low-friction piston construction for use in an oil-fed cylinder bore with the piston skirt relieved to define lands that are coated with SFL (graphite, MoS.sub.2, BN, and a special expoxy resin). A method of making such piston construction including provision of asperities on the skirt wall onto which the SFL coating is thermally sprayed and formation of small pockets at the mouth of the asperities to additionally act as oil replenishing reservoirs. A method of using such piston construction in an engine which comprises provisions of a slightly increased gap between the piston and cylinder wall and formation of a transferred SFL coating from the piston to the cylinder wall resulting in two polished microsmooth mating coatings, each attractive to oil films.

Abstract: A thermally sprayable powder having grains comprising: a core of solid lubricant particles comprised of at least graphite and MoS.sub.2 (others may include Bn, NaF, LiF, CaF.sub.2, and WS.sub.2); and a thin, soft metal shell (Ni, Co, Fe, Zn, Sn, Mg, or Cu) encapsulating such core. Some core particles may also be hard, wear-resistant particles from the group consisting of SiC, NiCrAl, FeMn, FeCrAl, FeWNiVCr, NiCrMoVW, FeCrMoWV, CoFeNiCrMoWV, NiCrMoV, and CoMoCrVW.

Abstract: A low-friction piston construction for use in an oil-fed cylinder bore with the piston skirt relieved to define lands that are coated with SFL (graphite, MoS.sub.2, BN, and a special expoxy resin). A method of making such piston construction including provision of asperities on the skirt wall onto which the SFL coating is thermally sprayed and formation of small pockets at the mouth of the asperities to additionally act as oil replenishing reservoirs. A method of using such piston construction in an engine which comprises provisions of a slightly increased gap between the piston and cylinder wall and formation of a transferred SFL coating from the piston to the cylinder wall resulting in two polished microsmooth mating coatings, each attractive to oil films.

Abstract: An adjustable valve system for an engine includes an axially shiftable camshaft with a plurality of cam lobes for actuating engine valves, with at least one of the lobes having a profile which varies as a function of the axial position of the lobe and camshaft. A valve lifter for use with a camshaft according to the invention includes a concave arcuate surface with a matching convex arcuate surface on a camshaft rubbing block pivotably mounted to the lifter. The lifter and rubbing block have a matching keyway and spline formed so that the rubbing block may accommodate changes in the cam position by pivoting about an imaginary axis which is perpendicular to the axis of the camshaft while being restrained by the spline and keyway from rotating about an axis parallel to the camshaft.

Abstract: An adjustable valve system for an engine includes an axially shiftable camshaft with a plurality of cam lobes for actuating engine valves, with at least one of the lobes having a profile which varies as a function of the axial position of the lobe and camshaft. A bucket tappet includes a camshaft contact button which is mounted to a cradle and pivot pad such that the contact button and cradle will be allowed to pivot in response to axial shifting of the camshaft.

Abstract: An adjustable valve system for an engine includes an axially shiftable camshaft with a plurality of cam lobes for actuating engine valves, with at least one of the lobes having a profile which varies as a function of the axial for use with a camshaft according to the invention includes a concave arcuate surface with a matching convex arcuate surface on a camshaft rubbing block pivotably mounted to the lifter. The lifter and rubbing block have a matching keyway and spline formed so that the rubbing block may accommodate changes in the cam position by pivoting about an imaginary axis which is perpendicular to the axis of the camshaft while being restrained by the spline and keyway from rotating about an axis parallel to the camshaft.

Abstract: An internal combustion engine having an air cell combustion system includes a cylinder block having at least one bore with a piston reciprocably housed therein, and a cylinder head attached to a cylinder block, with the cylinder block, piston and cylinder head defining a combustion chamber. A reservoir for air compressed by the piston is delimited by a counterbore in the deck surface of the cylinder block and by an annular space formed in the cylinder head. A number of passages extend tangentially from the reservoir into the combustion chamber.

Abstract: A composite engine block for an internal combustion engine having a fluid cooling jacket, comprising a bipartite liner structure with metal (i.e., aluminum alloy or cast iron) defining at least the combustion zone walls, the structure having one or more open cylinders of a first part mateable with a corresponding cylinder head of a second part, the first part having (i) an integral base plate extending transversely outwardly from the cylinder to define a lower imperforate membrane for the bottom of the cooling fluid jacket, and (ii) walls extending dependently from the base plate to support a crankshaft for rotation about an axis transverse to the cylinder, the second part having an integral top plate extending transversely outwardly over the cylinder head to define an upper imperforate membrane for the top of the cooling fluid jacket; (b) a tri-partite skin structure comprised of nonmetallic light weight, vibration damping material (i.e.