Abstract: Electromechanical devices and methods of forming coating layers thereon are provided. The electromechanical devices include components each having one or more surfaces formed of one or more metallic materials and susceptible to operating environments having temperatures in excess of 150° C. for a long term, and electrically insulative coating layers formed on the one or more surfaces of the components. The coating layer is configured to survive in operating environments having temperatures in excess of 180° C. for a long term.

Abstract: A spark plug comprises a shell having a substantially cylindrical threaded portion for threadable engagement in a cylinder head of an internal combustion engine, an insulator disposed coaxially in the shell, a center electrode disposed coaxially in the insulator, a side ground electrode having a first end coupled to the shell and a second end facing an end of the center electrode to define a spark discharge gap therebetween, and an electrode tip portion secured to either the side ground electrode or the center electrode proximate the spark discharge gap. The tip portion is formed from an alloy comprising from about 60 to about 70 percent by weight iridium, from about 30 to about 35 percent by weight rhodium, from 0 to about 10 percent by weight nickel, from about 3500 to about 4500 parts per million tantalum, and from about 100 to about 200 parts per million zirconium.

Abstract: A method of manufacturing a spark plug, the method including the step of: securing an electrode tip to at least one of a side ground electrode or a center electrode of the spark plug, the electrode tip comprising a platinum-based alloy comprising 20 to 35% by weight of palladium, from greater than 0 to 15% by weight iridium, and the balance of the alloy being platinum, all % by weight being based on the total weight of the alloy.

Abstract: A side electrode for a spark plug is provided. The side electrode includes a side wire having a first end and a second end; an opening proximate to the first end, the opening extending from a first surface of the side wire to a second surface of the side wire, wherein the first surface has a flared portion proximate to the opening; and an electrode tip secured to the first end of the side wire, the electrode tip having a tip portion and a shaft portion, wherein the tip portion is located on the second surface and the shaft portion is secured to the side wire by engaging the flared portion.

Abstract: A spark plug comprises a shell having a substantially cylindrical threaded portion for threadable engagement in a cylinder head of an internal combustion engine, an insulator disposed coaxially in the shell, a center electrode disposed coaxially in the insulator, a side ground electrode having a first end coupled to the shell and a second end facing an end of the center electrode to define a spark discharge gap therebetween, and an electrode tip portion secured to either the side ground electrode or the center electrode proximate the spark discharge gap. The tip portion is formed from an alloy comprising from about 60 to about 70 percent by weight iridium, from about 30 to about 35 percent by weight rhodium, from 0 to about 10 percent by weight nickel, from about 3500 to about 4500 parts per million tantalum, and from about 100 to about 200 parts per million zirconium.

Abstract: A method of manufacturing a spark plug, the method including the step of: securing an electrode tip to at least one of a side ground electrode or a center electrode of the spark plug, the electrode tip comprising a platinum-based alloy comprising 20 to 35% by weight of palladium, from greater than 0 to 15% by weight iridium, and the balance of the alloy being platinum, all % by weight being based on the total weight of the alloy.

Abstract: A spark plug and an alloy for an electrode tip of a spark plug is disclosed herein. The spark plug having: an insulator shell; a center electrode inside the insulator shell such that one end of the center electrode protrudes from the insulator shell; a metal shell exterior to the insulator shell; a side ground electrode having one end coupled to the metal shell and the other end facing the protruding end of the center electrode to form a spark discharge gap between the center electrode and the side ground electrode; and an electrode tip secured to at least one of the side ground electrode or the center electrode, located at the spark discharge gap, the electrode tip comprising a platinum-based alloy comprising 20 to 35% by weight of palladium, from greater than 0 to 15% by weight iridium, and the balance of the alloy being platinum, all % by weight being based on the total weight of the alloy.

Abstract: A spark plug comprises a shell having a substantially cylindrical threaded portion for threadable engagement in a cylinder head of an internal combustion engine, an insulator disposed coaxially in the shell, a center electrode disposed coaxially in the insulator, a side ground electrode having a first end coupled to the shell and a second end facing an end of the center electrode to define a spark discharge gap therebetween, and an electrode tip portion secured to either the side ground electrode or the center electrode proximate the spark discharge gap. The tip portion is formed from an alloy comprising from about 60 to about 70 percent by weight iridium, from about 30 to about 35 percent by weight rhodium, from 0 to about 10 percent by weight nickel, from about 3500 to about 4500 parts per million tantalum, and from about 100 to about 200 parts per million zirconium.

Abstract: A spark plug and an alloy for an electrode tip of a spark plug is disclosed herein. The spark plug having: an insulator shell; a center electrode inside the insulator shell such that one end of the center electrode protrudes from the insulator shell; a metal shell exterior to the insulator shell; a side ground electrode having one end coupled to the metal shell and the other end facing the protruding end of the center electrode to form a spark discharge gap between the center electrode and the side ground electrode; and an electrode tip secured to at least one of the side ground electrode or the center electrode, located at the spark discharge gap, the electrode tip comprising a platinum-based alloy comprising 20 to 35% by weight of palladium, from greater than 0 to 15% by weight iridium, and the balance of the alloy being platinum, all % by weight being based on the total weight of the alloy.

Abstract: A side electrode for a spark plug is provided. The side electrode includes a side wire having a first end and a second end; an opening proximate to the first end, the opening extending from a first surface of the side wire to a second surface of the side wire, wherein the first surface has a flared portion proximate to the opening; and an electrode tip secured to the first end of the side wire, the electrode tip having a tip portion and a shaft portion, wherein the tip portion is located on the second surface and the shaft portion is secured to the side wire by engaging the flared portion.

Abstract: A spark plug comprising: an insulator shell; a center electrode inside the insulator shell such that one end of the center electrode protrudes from the insulator shell; a metal shell exterior to the insulator shell; a side ground electrode having one end coupled to the metal shell and the other end facing the protruding end of the center electrode to form a spark discharge gap between the center electrode and the side ground electrode; and a metal tip on at least one of the side ground electrode or the center electrode, located at the spark discharge gap, that is a platinum-based alloy including 23-35 weight percent palladium, greater than 0 to 10 weight percent iridium and the balance being platinum.

Abstract: A spark plug comprises a shell having a substantially cylindrical threaded portion for threadable engagement in a cylinder head of an internal combustion engine, an insulator disposed coaxially in the shell, a center electrode disposed coaxially in the insulator, a side ground electrode having a first end coupled to the shell and a second end facing an end of the center electrode to define a spark discharge gap therebetween, and an electrode tip portion secured to either the side ground electrode or the center electrode proximate the spark discharge gap. The tip portion is formed from an alloy comprising from about 60 to about 70 percent by weight iridium, from about 30 to about 35 percent by weight rhodium, from 0 to about 10 percent by weight nickel, from about 3500 to about 4500 parts per million tantalum, and from about 100 to about 200 parts per million zirconium.

Abstract: A spark plug comprising: an insulator shell; a center electrode inside the insulator shell such that one end of the center electrode protrudes from the insulator shell; a metal shell exterior to the insulator shell; a side ground electrode having one end coupled to the metal shell and the other end facing the protruding end of the center electrode to form a spark discharge gap between the center electrode and the side ground electrode; and a metal tip on at least one of the side ground electrode or the center electrode, located at the spark discharge gap, that is a platinum-based alloy including 23-35 weight percent palladium, greater than 0 to 10 weight percent iridium and the balance being platinum.