Abstract: A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product.

Abstract: A method of near net shaping a rare earth permanent magnet and a permanent magnet. The method includes introducing a magnetic material powder into a die, closing the die and shock compacting the powder in the die and sintering the compacted magnet powder to form the rare earth permanent magnet part. In one form, the magnetic material being subjected to compaction is a mixture made up of two or more different magnetic material powder precursors. Additional materials may be added to the mixture. One such additional material may be a lubricant to reduce the likelihood of cracking, while another may be a coating to provide oxidation protection of the mixture. Evacuation or inert environments may also be used either prior to or in conjunction with the sintering or related high-temperature part of the process.

Abstract: A low friction coating for an internal combustion engine and a method of forming a low friction surface on at least one of the engine's friction-sensitive components. In one form, a solid lubricant precursor additive is combined with motor oil such that upon work being performed on the combination by adjacently-interacting engine components, the solid lubricant tribochemically reacts to form a friction-reducing coating or film. In one preferred form, the coating or film is triboformed on a cylinder bore or a liner configured to fit within the bore. The reciprocating movement between the cylinder or liner and a piston and/or piston rings promotes in-situ formation of the layer after the engine has already been manufactured rather than during engine fabrication or assembly.

Abstract: A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product.

Abstract: An oil filter and oil-additive dispensing device comprising an oil filter and oil additive replenishment system further comprising: a full-flow oil filter; a by-pass oil filter; an oil additive dispensing system; and an on-vehicle controller to dispense additive as required, track additive consumption and signal the need for a replacement system is described. Also a method of using such oil filter and oil-additive dispensing device to extend the useful life of lubricating oil in a vehicle engine is described.

Abstract: A low friction coating for an internal combustion engine and a method of forming a low friction surface on at least one of the engine's friction-sensitive components. In one form, a solid lubricant precursor additive is combined with motor oil such that upon work being performed on the combination by adjacently-interacting engine components, the solid lubricant tribochemically reacts to form a friction-reducing coating or film. In one preferred form, the coating or film is triboformed on a cylinder bore or a liner configured to fit within the bore. The reciprocating movement between the cylinder or liner and a piston and/or piston rings promotes in-situ formation of the layer after the engine has already been manufactured rather than during engine fabrication or assembly.

Abstract: One embodiment includes an automotive powertrain component and a bearing. The automotive powertrain component has a first surface and moves during use thereof. The bearing assists movement of the automotive powertrain component and has a second surface that opposes the first surface of the automotive powertrain component. Multiple micropores are located on a portion or more of the first surface, of the second surface, or of both the first and second surfaces. The micropores retain lubricant therein. In use, the lubricant can be lifted above respective openings of the micropores and into a space located between the first and second surfaces.

Abstract: A valve assembly includes a tubular valve stem guide and a valve having a valve stem slidable in the bore of the valve stem guide. A lower valve stem seal has an annular body surrounding the valve stem and a skirt sealing with the valve stem guide. An upper valve stem seal has an annular body sealingly mounted on the valve stem and a skirt portion overlapping with the annular body of the lower valve stem seal during the reciprocating movement of the valve stem so that the upper and lower valve stem seals cooperate to prevent flow of oil to the bore of the valve stem guide. The valve stem is coated with a diamond-like carbon coating or a hard nitride coating, and the valve stem guide is of powered metal construction with approximately 1% by weight solid lubricant such as molybdenum disulfide or tungsten disulfide.

Abstract: A valve assembly includes a tubular valve stem guide and a valve having a valve stem slidable in the bore of the valve stem guide. A lower valve stem seal has an annular body surrounding the valve stem and a skirt sealing with the valve stem guide. An upper valve stem seal has an annular body sealingly mounted on the valve stem and a skirt portion overlapping with the annular body of the lower valve stem seal during the reciprocating movement of the valve stem so that the upper and lower valve stem seals cooperate to prevent flow of oil to the bore of the valve stem guide. The valve stem is coated with a diamond-like carbon coating or a hard nitride coating, and the valve stem guide is of powered metal construction with approximately 1% by weight solid lubricant such as molybdenum disulfide or tungsten disulfide.

Abstract: An engine assembly may include an engine block defining a cylinder bore, a cylinder head fixed to the engine block, and a valve seat insert. The cylinder head may include an intake port, defining an inlet in fluid communication with an air source and an outlet in fluid communication with the cylinder bore. The valve seat may be defined at the outlet of the intake port and may include a stepped region. The stepped region may define a seating surface extending radially outward from the intake port. The seating surface may include a series of protrusions circumferentially spaced from one another around the outlet and forming a series of recesses therebetween. The valve seat insert may be located within the stepped region and may include a first axial end surface abutting the protrusions on the seating surface.

Abstract: A method is disclosed for initiating oil injection into a cylinder of an internal combustion engine prior to engine start-up, the oil injection protecting the engine from damage caused by insufficient lubrication during the start-up. The method includes processing data to modulate a lubrication initiation modifier and initiating the oil injection on the basis of the lubrication initiation modifier.

Abstract: A crankshaft has spaced-apart cheeks and a cylindrical surface between the cheeks. A split ring bearing assembly has first and second bearing parts that join to encircle the cylindrical surface. First and second split ring seal assemblies each have first and second seal parts that join to encircle and sealingly contact with the cylindrical surface on each side of the split ring bearing assembly. A journal includes a first and second journal halves having cylindrical recesses receiving the crankshaft so that the split ring bearing assembly bears upon the journal and the first and second split ring seal assemblies sealingly contact with the journal halves. A lube fill fitting is provided in the journal for the introduction of lubricant which is permanently sequestered between the first and second split ring seal assemblies to provide sealed lubrication of the split ring bearing assemblies.

Abstract: The present invention utilizes rolling elements, such as balls or rollers acting as bearings carried in openings in the skirt or equivalent portion of a piston, to engage the cylinder walls and replace the sliding bearings of the skirt with the roller elements in the skirt. The rolling elements then absorb all or some of the thrust loads conventionally absorbed by the skirt walls sliding along surfaces of an associated cylinder and thereby reduce the friction forces developed by the reciprocating action of the piston skirt.

Abstract: An oil filter and oil-additive dispensing device comprising an oil filter and oil additive replenishment system further comprising: a full-flow oil filter; a by-pass oil filter; an oil additive dispensing system; and an on-vehicle controller to dispense additive as required, track additive consumption and signal the need for a replacement system is described. Also a method of using such oil filter and oil-additive dispensing device to extend the useful life of lubricating oil in a vehicle engine is described.

Abstract: A major engine casting, such as an engine block or a cylinder head, fabricated of either magnesium or aluminum alloy, has a cast-in-place metal tube or form embedded within it. The tube or form enables circulation of liquid while substantially physically isolating the casting alloy from the circulating liquid and thereby restricting or eliminating corrosive interaction between them.

Abstract: Systems and methods produce forged powder metal parts respectively comprising a transverse feature. A system may comprise a powder metal die, a sintering oven, a forging apparatus, a core material, and a powder metal. The powder metal die may receive and compact the core material and the powder metal to form a compacted powder metal part with at least a portion of the core material embedded therein to define a transverse feature in the compacted powder metal part. The sintering oven may receive and sinter the compacted powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during sintering. The forging apparatus may receive and forge the sintered powder metal part with the core material remaining embedded therein to maintain the definition of the transverse feature during forging with the embedded core material being removable from the forged powder metal thereafter.

Abstract: An engine assembly may include an engine block defining a cylinder bore, a cylinder head fixed to the engine block, and a valve seat insert. The cylinder head may include an intake port, defining an inlet in fluid communication with an air source and an outlet in fluid communication with the cylinder bore. The valve seat may be defined at the outlet of the intake port and may include a stepped region. The stepped region may define a seating surface extending radially outward from the intake port. The seating surface may include a series of protrusions circumferentially spaced from one another around the outlet and forming a series of recesses therebetween. The valve seat insert may be located within the stepped region and may include a first axial end surface abutting the protrusions on the seating surface.

Abstract: A method is disclosed for initiating oil injection into a cylinder of an internal combustion engine prior to engine start-up, the oil injection protecting the engine from damage caused by insufficient lubrication during the start-up. The method includes processing data to modulate a lubrication initiation modifier and initiating the oil injection on the basis of the lubrication initiation modifier.

Abstract: A crankshaft has spaced-apart cheeks and a cylindrical surface between the cheeks. A split ring bearing assembly has first and second bearing parts that join to encircle the cylindrical surface. First and second split ring seal assemblies each have first and second seal parts that join to encircle and sealingly contact with the cylindrical surface on each side of the split ring bearing assembly. A journal includes a first and second journal halves having cylindrical recesses receiving the crankshaft so that the split ring bearing assembly bears upon the journal and the first and second split ring seal assemblies sealingly contact with the journal halves. A lube fill fitting is provided in the journal for the introduction of lubricant which is permanently sequestered between the first and second split ring seal assemblies to provide sealed lubrication of the split ring bearing assemblies.

Abstract: The present invention utilizes rolling elements, such as balls or rollers acting as bearings carried in openings in the skirt or equivalent portion of a piston, to engage the cylinder walls and replace the sliding bearings of the skirt with the roller elements in the skirt. The rolling elements then absorb all or some of the thrust loads conventionally absorbed by the skirt walls sliding along surfaces of an associated cylinder and thereby reduce the friction forces developed by the reciprocating action of the piston skirt.