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 precision cast connecting rod which has an elongate tubular shank member defining a hollow section for producing desired stiffness to weight characteristics. Piston and crankpin connecting members are attached to opposite ends of the shank member. The connecting members are provided with passages which extend axially therewithin from the hollow section. Defined within the elongate tubular shank member is a radially extending central aperture.

Abstract: A method of making a connecting rod for attachment to a bearing journal by separation of parts of the connecting rod, comprising: (a) forging a powder metal sintered preform to provide a one-piece connecting rod having an annular wall defining a crank opening with a center axis and with stress risers for establishing a cracking plane that extends across said crank opening; (b) providing access for a compression coupling across the cracking plane; (c) while at ambient conditions, applying tension substantially uniformly across the cracking plane to propogate fracture from the stress risers along said cracking plane and thereby separate the connecting rod into a cap and body with cracked surfaces; and (d) remating the cap and body by applying a compression coupling through the access to draw said cap and body together under guidance and with metal yielding pressure to effect substantially an exact rematch of said cracked surfaces.

Abstract: A method of making a connecting rod for attachment to a bearing journal by separation of parts of the connecting rod, comprising: (a) forging a powder metal sintered preform to provide a one-piece connecting rod having an annular wall defining a crank opening with a center axis and with stress risers for establishing a cracking plane that extends across said crank opening; (b) providing access for a compression coupling across the cracking plane; (c) while at ambient conditions, applying tension substantially uniformly across the cracking plane to propagate fracture from the stress risers along said cracking plane and thereby separate the connecting rod into a cap and body with cracked surfaces; and (d) remating the cap and body by applying a compression coupling through the access to draw said cap and body together under guidance and with metal yielding pressure to effect substantially an exact rematch of said cracked surfaces.

Abstract: A precision cast connecting rod which has an elongate tubular shank member defining a hollow section for producing desired stiffness to weight characteristics. Piston and crankpin connecting members are attached to opposite ends of the shank member. The connecting members are provided with passages which extend axially therewithin from the hollow section. Defined within the elongate tubular shank member is a radially extending central aperture. A precision casting method for preparing the hollow connecting rod includes forming an elongate core with a locating member positioned at each end thereof and a disk-shaped protuberance extending radially therefrom. The core is secured in a die and defines a cavity therebetween for preparing a pattern of the connecting rod using a molding material which substantially encapsulates the core within the cavity. After removing the pattern from the die, coatings of refractory material are applied to form a shell mold which encrusts the pattern.

Abstract: A precision cast connecting rod which has an elongate tubular shank member defining a hollow section for producing desired stiffness to weight characteristics. Piston and crankpin connecting members are attached to opposite ends of the shank member. The connecting members are provided with passages which extend axially therewithin from the hollow section. Defined within the elongate tubular shank member is a radially extending central aperture. A precision casting method for preparing the hollow connecting rod includes forming an elongate core with a locating member positioned at each end thereof and a disk-shaped protuberance extending radially therefrom. The core is secured in a die and defines a cavity therebetween for preparing a pattern of the connecting rod using a molding material which substantially encapsulates the core within the cavity. After removing the pattern from the die, coatings of refractory material are applied to form a shell mold which encrusts the pattern.

Abstract: A method of making a connecting rod for attachment to a bearing journal by separation of parts of the connecting rod, comprising: (a) forging a powder metal sintered preform to provide a one-piece connecting rod having an annular wall defining a crank opening with a center axis and with stress risers for establishing a cracking plane that extends across said crank opening; (b) providing access for a compression coupling across the cracking plane; (c) while at ambient conditions, applying tension substantially uniformly across the cracking plane to propogate fracture from the stress risers along said cracking plane and thereby separate the connecting rod into a cap and body with cracked surfaces; and (d) remating the cap and body by applying a compression coupling through the access to draw said cap and body together under guidance and with metal yielding pressure to effect substantially an exact rematch of said cracked surfaces.

Abstract: A method of making a connecting rod for attachment to a bearing journal by separation of parts of the connecting rod, comprising: (a) forging a powder metal sintered preform to provide a one-piece connecting rod having an annular wall defining a crank opening with a center axis and with stress risers for establishing a cracking plane that extends across said crank opening; (b) providing access for a compression coupling across the cracking plane; (c) while at ambient conditions, applying tension substantially uniformly across the cracking plane to propogate fracture from the stress risers along said cracking plane and thereby separate the connecting rod into a cap and body with cracked surrfaces; and (d) remating the cap and body by applying a compression coupling through the access to draw said cap and body together under guidance and with metal yielding pressure to effect substantially an exact rematch of said cracked surfaces.