Abstract: A method of forming an insulated composite piston head may include: creating a preformed aluminum or aluminum alloy foam core; suspending the preformed foam core in a piston head mold; forming a molded piston head and removing it from the mold; depositing an insulating material on at least one surface of the molded piston head; performing at least one machining operation on the molded piston head so it conforms to a predetermined specification for the insulated composite piston head; and optionally applying a lubricious piston coating to at least a portion of the outer surface of the insulated composite piston head.

Abstract: An insulated composite piston head that includes three or more layers is formed and used in a combustion engine. The first layer is an aluminum or aluminum alloy foam core. The second layer is a metal layer that at least partially encapsulates the foam core; wherein the metal layer is selected to be aluminum or an aluminum alloy. The third layer is a layer of an insulating material located on at least one surface of the metal layer. The deposition of the insulating layer is accomplished via the use of a coaxial laser process.

Abstract: An insulated composite piston head that includes three or more layers is formed and used in a combustion engine. The first layer is an aluminum or aluminum alloy foam core. The second layer is a metal layer that at least partially encapsulates the foam core; wherein the metal layer is selected to be aluminum or an aluminum alloy. The third layer is a layer of an insulating material located on at least one surface of the metal layer. The deposition of the insulating layer is accomplished via the use of a coaxial laser process.