Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components, such as camshaft lobes, with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.

Abstract: An automotive engine valve stem, engine valve and method of producing both. The valve includes a head and a stem joined to the head. Lightweight, high-temperature materials, such as titanium-based materials may be used to make up at least a the majority of the valve. These materials are combined with fabrication techniques that may vary between the head and the stem, where at least a part of the valve is made by dynamic magnetic compaction. While a majority of the stem may be made from a titanium-based powder material, its tip may be made of a high strength hardened material, such as a steel alloy. The valve head may be made by single press and sintering, double press and sintering, forging and machining, forging and sintering, and dynamic magnetic compaction and sintering.

Abstract: A hydraulic control system to provide an oil or pressurized fluid supply to a variable cam phasing system in an engine is provided. The hydraulic control system includes a valve housing attachable to a front cover assembly of the engine; a first valve installed in the housing; and an inlet passage defined by the front cover assembly hydraulically communicating with the first valve in the housing to carry pressurized fluid from a fluid source to the first valve. A first and a second outlet passage defined by the housing hydraulically communicates with the first valve to allow the pressurized fluid to flow to the cam phasing system, thereby variably moving a camshaft assembly operatively connected to the cam phasing system.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A control system comprising a spark knock detection module that detects a spark knock in an engine of a hybrid vehicle, and a torque control module that selectively regulates an engine torque output and an electric machine torque output based on the spark knock. A method comprising detecting a spark knock in an engine of a hybrid vehicle, and selectively regulating an engine torque output and an electric machine torque output based on the spark knock.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A valve train for use in an engine is provided. The valve train includes a rocker arm assembly having a valve side arm and a cam side arm. A valve is coupled to the engine and is in contact with the valve side arm. A pushrod is reciprocatable by a camshaft and is in contact with the cam side arm. An overload feature is located on at least one of the rocker arm assembly or the pushrod. The overload feature has a reduced cross-sectional area calibrated to activate at a predefined load.

Abstract: An engine assembly may include a cam phaser assembly coupled to a concentric camshaft. The cam phaser assembly may include first and second plate assemblies that have first and second vanes, an oil chamber housing located axially between the first and second plate assemblies, an oil distribution member, and a first fastener. The first and second plates may define first and second fastener passages. The oil chamber housing may define first and second chambers and a first central bore. The first vane may extend into the first chamber and the second vane may extend into the second chamber. The oil distribution member may be located within the central bore of the oil chamber housing and may define a third fastener passage. The first fastener may extend through the first, second, and third fastener passages and couple the cam phaser assembly to an outer shaft of the concentric camshaft.

Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: An apparatus for providing pressurized fuel for an engine includes an engine starting apparatus including an electric motor operative to crank the engine and a fuel pump operatively coupled to the electric motor.

Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.

Abstract: A control system comprising a spark knock detection module that detects a spark knock in an engine of a hybrid vehicle, and a torque control module that selectively regulates an engine torque output and an electric machine torque output based on the spark knock. A method comprising detecting a spark knock in an engine of a hybrid vehicle, and selectively regulating an engine torque output and an electric machine torque output based on the spark knock.

Abstract: A hydraulic control system to provide an oil or pressurized fluid supply to a variable cam phasing system in an engine is provided. The hydraulic control system includes a valve housing attachable to a front cover assembly of the engine; a first valve installed in the housing; and an inlet passage defined by the front cover assembly hydraulically communicating with the first valve in the housing to carry pressurized fluid from a fluid source to the first valve. A first and a second outlet passage defined by the housing hydraulically communicates with the first valve to allow the pressurized fluid to flow to the cam phasing system, thereby variably moving a camshaft assembly operatively connected to the cam phasing system.

Abstract: An automotive engine valve stem, engine valve and method of producing both. The valve includes a head and a stem joined to the head. Lightweight, high-temperature materials, such as titanium-based materials may be used to make up at least a the majority of the valve. These materials are combined with fabrication techniques that may vary between the head and the stem, where at least a part of the valve is made by dynamic magnetic compaction. While a majority of the stem may be made from a titanium-based powder material, its tip may be made of a high strength hardened material, such as a steel alloy. The valve head may be made by single press and sintering, double press and sintering, forging and machining, forging and sintering, and dynamic magnetic compaction and sintering.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: An engine assembly may include an engine structure, a crankshaft, a camshaft, a balance shaft, and first and second gears. The crankshaft, camshaft, and balance shaft may each be rotatably supported by the engine structure. The camshaft may be rotationally driven by the crankshaft and the first gear may be coupled to the camshaft. The second gear may be fixed for rotation with the balance shaft and meshingly engaged with and driven by the first gear.

Abstract: An engine assembly may include a cam phaser assembly coupled to a concentric camshaft. The cam phaser assembly may include first and second plate assemblies that have first and second vanes, an oil chamber housing located axially between the first and second plate assemblies, an oil distribution member, and a first fastener. The first and second plates may define first and second fastener passages. The oil chamber housing may define first and second chambers and a first central bore. The first vane may extend into the first chamber and the second vane may extend into the second chamber. The oil distribution member may be located within the central bore of the oil chamber housing and may define a third fastener passage. The first fastener may extend through the first, second, and third fastener passages and couple the cam phaser assembly to an outer shaft of the concentric camshaft.

Abstract: A process for powder metal mold casting of three-dimensional parts is disclosed wherein a casting of complex parts is facilitated.