Abstract: A hollow poppet valve (31) is disclosed, in which a stem portion (13) includes a flared fillet portion (17), having a wall thickness (T), and a downwardly-extending cylindrical portion (33;51), having a cylindrical external surface (35). In the main embodiment, the valve includes a cap member (15) defining a seat face (25), and a cylindrical internal surface (39), the internal and external surfaces (39,35) being closely spaced apart, defining an interface having an axial length (L), and being consumed by a weld (43). Preferably, the length (L) of the weld (43) is equal to at least 1.1 times the thickness (T). The fillet portion (17) defines an internal fillet radius (R1), greater than 0.3 times the thickness (T), and near the radius (R1) is a transition region (TR). The present invention improves fatigue strength of the poppet valve by separating the transition region (TR) from the weld (43) so that there is overlap for no more than a minor portion of the weld.

Abstract: An ultra light popper valve for an internal combustion engine. The valve is formed by cold forming a blank into an elongated cup having an extremely thin wall and a flared open end onto which a cap is welded, the bosom end of the cup which defines the tip end of the valve having a wall section which is substantially of the thickness of the original blank. In accordance with one aspect of the invention, a keeper groove is formed adjacent the tip end as part of the cold forming process.

Abstract: An ultra light weight poppet valve which includes elements for controlling the temperature of the valve during operation. The valve is of the type which is formed as an elongated cup having a flared open end to which a cap is fixed and in which an extremely thin-wall section is maintained all the way to a closed tip end. Temperature control elements include multiple thin-walled elements in nesting relationship to define multiple interior chambers, and a plug member received within the stem portion of the valve and maintained in place by inwardly deflecting the stem portion.

Abstract: An ultra light poppet valve for an internal combustion engine. The valve is formed by cold forming a blank into an elongated cup having an extremely thin wall and a flared open end onto which a cap is welded, the bottom end of the cup which defines the tip end of the valve having a wall section which is substantially of the thickness of the original blank. In accordance with one aspect of the invention, a keeper groove is formed adjacent the tip end as part of the cold forming process.

Abstract: Wear resistant articles, especially valve seat inserts for internal combustion engines, are produced as sintered metal compacts comprising interspersed microzones of prealloyed austenitic stainless steel and softer ferrous metal, the microzones of austenitic stainless steel containing carbides and carbonitrides. The sintered compacts can be made by forming a green compact from prealloyed austenitic stainless steel powder atomizate blended with softer powdered ferrous metal component and powdered carbon, and sintering the green compact.