Abstract: A valve seat formed within an aluminum engine component includes a valve seat surface machined within the aluminum engine component, a layer of copper alloy material laser clad onto the valve seat surface of the aluminum engine component, the layer of copper alloy material having a thickness of less than 2.0 millimeters, and a layer of copper alloy/tool steel carbide material laser clad onto the layer of copper alloy material, the layer of copper alloy/tool steel carbide material having an average thickness of less than 0.5 millimeters, wherein the layer of copper alloy/tool steel carbide material has an outer surface that is machined to a final valve seat profile.

Abstract: A valve seat formed within an aluminum engine component includes a valve seat surface machined within the aluminum engine component, a layer of copper alloy material laser clad onto the valve seat surface of the aluminum engine component, the layer of copper alloy material having a thickness of less than 2.0 millimeters, and a layer of copper alloy/tool steel carbide material laser clad onto the layer of copper alloy material, the layer of copper alloy/tool steel carbide material having an average thickness of less than 0.5 millimeters, wherein the layer of copper alloy/tool steel carbide material has an outer surface that is machined to a final valve seat profile.

Abstract: An engine system includes: an internal combustion engine having a plurality of cylinders; a bypass valve arranged to receive exhaust output from at least a dedicated one of the cylinders and to selectively one of: direct the exhaust through an exhaust system to atmosphere; and direct the exhaust to an exhaust gas recirculation (EGR) valve; the EGR valve, where the EGR valve is configured to, when open, enable flow of the exhaust to an intake manifold of the internal combustion engine; and an intake air valve located between an air cleaner and a mass airflow (MAF) sensor and configured to, when open, enable flow of ambient air to the intake manifold.

Abstract: An engine system includes: an internal combustion engine having a plurality of cylinders; a bypass valve arranged to receive exhaust output from at least a dedicated one of the cylinders and to selectively one of: direct the exhaust through an exhaust system to atmosphere; and direct the exhaust to an exhaust gas recirculation (EGR) valve; the EGR valve, where the EGR valve is configured to, when open, enable flow of the exhaust to an intake manifold of the internal combustion engine; and an intake air valve located between an air cleaner and a mass airflow (MAF) sensor and configured to, when open, enable flow of ambient air to the intake manifold.

Abstract: An internal combustion gasoline engine includes an air heater coupled to an intake duct of the engine in a heat transfer relationship with air in the intake duct. A combustion pre-chamber is also formed in the head of the engine. The pre-chamber is at least partially separated from the combustion chamber by a wall. One or more apertures are formed through the wall and provide fluid communication paths from the combustion chamber to the pre-chamber, feeding a mixture of air and fuel from the combustion chamber to the pre-chamber. The apertures further define a plurality of combustion paths allowing ignited fuel and air from the pre-chamber to efficiently enter and combust the fuel and air mixture within the combustion chamber. The air heater and the combustion pre-chamber increase combustion efficiency from a first efficiency level to a second efficiency level greater than the first efficiency level.

Abstract: An exhaust gas recirculation (EGR) system with independent intake air compressor includes an engine having at least one cylinder communicating with a cylinder exhaust passage. A bypass valve positioned in the cylinder exhaust passage when selectively aligned in a first position directs all exhaust from the at least one cylinder to an exhaust passage and when selectively aligned in a second position directs all exhaust from the at least one cylinder into an EGR dedicated passage. An intake manifold is in communication with the EGR dedicated passage. An electrically powered eBoost compressor when activated receives atmospheric air and generates a required boosted air pressure flow during a mid-load engine operation portion and a high-load engine operation portion for introduction into the intake manifold independently of the EGR dedicated passage. The eBoost compressor is deactivated during a low-load engine operation portion.

Abstract: A pushrod valvetrain combustion system assembly for an internal combustion engine includes a two-valve pushrod assembly and a cylinder top that forms a portion of a cylinder head. The cylinder top has a single intake port, a single exhaust port, a spark plug bore, and a fuel injector bore. The pushrod assembly includes an intake valve positioned in the intake port and an exhaust valve positioned in the exhaust port. The intake port and exhaust port are positioned adjacent each other and are positioned along an axis that intersects a center point of each of the ports. The intersecting axis is rotated relative to a centerline of the crankshaft of the engine, providing space for the spark plug bore and fuel injector bore to both be located in the cylinder top on a same side of the intersecting axis.

Abstract: A cylinder head assembly for an internal combustion engine includes a main body, a valve seat insert, and at least one flow passage extending through the main body. The main body may be formed from a first material and defines a recess configured to cooperate with an associated cylinder bore and piston to form a combustion chamber. The flow passage may extend through the main body from the recess. The valve seat insert may be disposed within the recess proximate to an end of the flow passage. The valve seat insert includes a thermally conductive layer of powdered metal having an upper side disposed adjacent to the main body, a hardness layer of powdered metal, and a machining layer of powdered metal.

Abstract: A multi-cylinder engine includes first and second subsets of cylinders. A dedicated-cylinder exhaust gas recirculation (EGR) system is associated with the second subset of cylinders. A plasma ignition system is disposed in the second subset of cylinders. A controller operates the plasma ignition system to control the plasma igniters to execute plasma discharges in the second subset of cylinders to generate residual exhaust gas, which is recirculated through the dedicated-cylinder EGR system to the intake air system for introduction into intake air.

Abstract: A pushrod valvetrain combustion system assembly for an internal combustion engine includes a two-valve pushrod assembly and a cylinder top that forms a portion of a cylinder head. The cylinder top has a single intake port, a single exhaust port, a spark plug bore, and a fuel injector bore. The pushrod assembly includes an intake valve positioned in the intake port and an exhaust valve positioned in the exhaust port. The intake port and exhaust port are positioned adjacent each other and are positioned along an axis that intersects a center point of each of the ports. The intersecting axis is rotated relative to a centerline of the crankshaft of the engine, providing space for the spark plug bore and fuel injector bore to both be located in the cylinder top on a same side of the intersecting axis.

Abstract: An engine assembly includes an engine block defining a cylinder, an exhaust system, and an exhaust gas recirculation system. A first exhaust valve is configured to control fluid communication from the cylinder to the exhaust system. A second exhaust valve is configured to control fluid communication from the cylinder to the exhaust gas recirculation system. The second exhaust valve is selectively activatable and deactivatable independently of the first exhaust valve.

Abstract: A multi-cylinder spark-ignition internal combustion engine (engine) that includes a dedicated-cylinder exhaust gas recirculation (EGR) system is described. The dedicated-cylinder EGR system includes a controllable exhaust gas diverter valve that selectively diverts all exhaust gas produced by one of the cylinders to an air intake system of the engine. A method for controlling the engine includes monitoring a parameter associated with operation of the dedicated-cylinder EGR system. Upon detecting a change in the parameter that indicates a change in operation of the dedicated-cylinder EGR system, a controller controls operation of the internal combustion engine to reduce an effective cylinder compression ratio.

Abstract: A multi-cylinder engine includes first and second subsets of cylinders. A dedicated-cylinder exhaust gas recirculation (EGR) system is associated with the second subset of cylinders. A plasma ignition system is disposed in the second subset of cylinders. A controller operates the plasma ignition system to control the plasma igniters to execute plasma discharges in the second subset of cylinders to generate residual exhaust gas, which is recirculated through the dedicated-cylinder EGR system to the intake air system for introduction into intake air.

Abstract: Provided herein are turbocharger manifolds, and turbocharger and exhaust gas recirculation (EGR) systems incorporating the same. The manifold comprises a body, at least one non-dedicated EGR vein, a dedicated EGR vein, and an EGR bypass valve in fluid communication with the dedicated EGR vein, wherein the dedicated EGR vein converges with the at least one non-dedicated EGR veins downstream from the EGR bypass valve. The dedicated EGR vein is in fluid communication with an EGR conduit. The EGR bypass valve can selectively allow or prevent fluid communication between the dedicated EGR vein and the EGR conduit. The EGR bypass valve can comprise a two-way valve having a gate movable from a first position to a second position. The manifold can comprise a one-piece construction with a turbocharger turbine housing.

Abstract: An engine control system of a vehicle includes a fuel control module that controls fuel injection of a first cylinder of an engine based on a first target air/fuel ratio that is fuel lean relative to a stoichiometric air/fuel ratio and that controls fuel injection of a second cylinder of the engine based on a second target air/fuel ratio that is fuel rich relative to stoichiometry. The first cylinder outputs exhaust to a first three way catalyst (TWC), and the second cylinder outputs exhaust to an exhaust gas recirculation (EGR) valve. An EGR control module controls opening of the EGR valve to: (i) a second TWC that reacts with nitrogen oxides (NOx) in the exhaust and outputs ammonia to a selective catalytic reduction (SCR) catalyst; and (ii) a conduit that recirculates exhaust back to an intake system of the engine.

Abstract: A multi-cylinder spark-ignition internal combustion engine includes a plurality of first and second intake valves disposed between the air intake system and a corresponding plurality of engine cylinders. The engine also includes a dedicated-cylinder exhaust gas recirculation (EGR) system including an exhaust runner fluidly connected between exhaust valve(s) of one of the cylinders and the air intake system of the engine. A controllable intake valve activation system is configured to control openings of the plurality of first and second intake valves. A controller is operatively connected to the engine and the controllable intake valve activation system, and includes an instruction set to monitor operation of the engine, and control openings of the plurality of first intake valves and control openings of the plurality of second intake valves to generate in-cylinder mixing of a cylinder charge that achieves combustion stability for an engine speed/load operating point.

Abstract: A method of operating a gasoline engine having a first subset of cylinders and a second subset of cylinders includes providing a flow of compressed air from a single-sequential compressor to the engine, selectively deactivating the first subset of cylinders, and igniting gasoline mixed with the compressed air in the second subset of cylinders. The single-sequential compressor includes a dual sided impeller having a first blade arrangement in fluid communication with a first air inlet, and an opposing second blade arrangement in fluid communication with a second air inlet. Additionally, deactivating the first subset of cylinders includes sealing the first subset of cylinders such that the flow of compressed air is provided only to the second subset of cylinders.

Abstract: An engine assembly includes a cylinder head having an intake side and an exhaust side opposite the intake side. The cylinder head has an intake port, an exhaust port, and a combustion chamber in fluid communication with the intake port and the exhaust port. The engine assembly further includes a port fuel injector coupled to the cylinder head. The port fuel injector is disposed closer to the exhaust side than to the intake side of the cylinder head. Further, the port fuel injector is fluid communication with the intake port to allow fuel to be injected directly into the intake port. The engine assembly further includes a direct fuel injector coupled to the cylinder head. The direct injector is in fluid communication with the combustion chamber to allow fuel to be injected directly into the combustion chamber.

Abstract: An engine control system of a vehicle includes a fuel control module that controls fuel injection of a first cylinder of an engine based on a first target air/fuel ratio that is fuel lean relative to a stoichiometric air/fuel ratio and that controls fuel injection of a second cylinder of the engine based on a second target air/fuel ratio that is fuel rich relative to stoichiometry. The first cylinder outputs exhaust to a first three way catalyst (TWC), and the second cylinder outputs exhaust to an exhaust gas recirculation (EGR) valve. An EGR control module controls opening of the EGR valve to: (i) a second TWC that reacts with nitrogen oxides (NOx) in the exhaust and outputs ammonia to a selective catalytic reduction (SCR) catalyst; and (ii) a conduit that recirculates exhaust back to an intake system of the engine.

Abstract: An engine assembly includes a cylinder head having an intake side and an exhaust side opposite the intake side. The cylinder head has an intake port, an exhaust port, and a combustion chamber in fluid communication with the intake port and the exhaust port. The engine assembly further includes a port fuel injector coupled to the cylinder head. The port fuel injector is disposed closer to the exhaust side than to the intake side of the cylinder head. Further, the port fuel injector is fluid communication with the intake port to allow fuel to be injected directly into the intake port. The engine assembly further includes a direct fuel injector coupled to the cylinder head. The direct injector is in fluid communication with the combustion chamber to allow fuel to be injected directly into the combustion chamber.