Abstract: An engine block assembly includes an engine block casting including a plurality of cylinder bores disposed in series, each cylinder having a cylinder wall. Outer engine block walls are peripheral to the cylinder walls. A channel is formed between outer peripheral surfaces of the cylinder walls and the outer engine block walls. A coolant passage fluidly connects through the outer block walls to the channel. A water jacket insert includes an upper flange, a strut portion and a lower flange. A plurality of orifices are formed in the strut portion. A compressible seal attached to the lower flange of the water jacket insert, which is assembled into the channel and conforms to a bottom portion of the channel.

Abstract: A bimetallic piston pin for a vehicle engine includes a tubular steel alloy shell, a first core member, a second core member and a middle core member. The tubular steel alloy shell includes a first end, a second end and a middle region. The tubular steel alloy shell also includes an interior surface and an exterior surface. The first core member may be disposed within the tubular steel alloy shell at the first end and the second core member may also disposed within the tubular steel alloy shell at the second end. The middle core member may be disposed within the tubular steel alloy shell between the first core member and the second core member.

Abstract: A sliding camshaft is provided which may include a base shaft, an over-molded trigger wheel, and a distal axially movable structure. The distal axially movable structure may further include a distal journal in addition to at least one standard journal and lobe packs. A control groove is defined in the distal axially movable structure. The over-molded trigger wheel is mounted on the distal axially movable structure. The over-molded trigger wheel is operatively configured to move between at least a first position and a second position together with the distal axially movable structure via engagement between the control groove and an actuator. The over-molded trigger wheel may be press fitted on distal axially movable structure and is adapted to accurately communicate with a sensor regardless of the position of the distal axially movable structure.

Abstract: A sliding camshaft is provided which may include a base shaft, an over-molded trigger wheel, and a distal axially movable structure. The distal axially movable structure may further include a distal journal in addition to at least one standard journal and lobe packs. A control groove is defined in the distal axially movable structure. The over-molded trigger wheel is mounted on the distal axially movable structure. The over-molded trigger wheel is operatively configured to move between at least a first position and a second position together with the distal axially movable structure via engagement between the control groove and an actuator. The over-molded trigger wheel may be press fitted on distal axially movable structure and is adapted to accurately communicate with a sensor regardless of the position of the distal axially movable structure.

Abstract: A method of manufacturing a sliding camshaft for an internal combustion engine includes providing the sliding camshaft from a steel alloy having a carbon content between 0.25% and 0.60%. The sliding camshaft is then processed with a carbon infusing heat treatment process, such as carburization or carbonitriding. After the sliding camshaft has been processed with the carbon infusing heat treatment process, the sliding camshaft is then processed with a quenching heat treatment process, such as a mar-quenching heat treatment process.

Abstract: A method of manufacturing a sliding camshaft for an internal combustion engine includes providing the sliding camshaft from a steel alloy having a carbon content between 0.25% and 0.60%. The sliding camshaft is then processed with a carbon infusing heat treatment process, such as carburization or carbonitriding. After the sliding camshaft has been processed with the carbon infusing heat treatment process, the sliding camshaft is then processed with a quenching heat treatment process, such as a mar-quenching heat treatment process.

Abstract: A sliding camshaft for shifting to a selected one of a plurality of selectable cam lobes includes an inner shaft and an outer shaft. The inner shaft has an external spline. The outer shaft has an inner surface, an outer surface, a coating, and an outer portion. The inner surface is subjectable to wear and is configured with an internal spline for transferring torque from and sliding axially on the external spline of the inner shaft. The outer surface is subjectable to wear and loading and is configured with the plurality of selectable cam lobes. The coating on the inner surface is for wear resistance. The outer portion is case hardened for wear resistance of the outer surface and to create a compressive residual stress in the outer portion for load carrying capability.

Abstract: A sliding camshaft for shifting to a selected one of a plurality of selectable cam lobes includes an inner shaft and an outer shaft. The inner shaft has an external spline. The outer shaft has an inner surface, an outer surface, a coating, and an outer portion. The inner surface is subjectable to wear and is configured with an internal spline for transferring torque from and sliding axially on the external spline of the inner shaft. The outer surface is subjectable to wear and loading and is configured with the plurality of selectable cam lobes. The coating on the inner surface is for wear resistance. The outer portion is case hardened for wear resistance of the outer surface and to create a compressive residual stress in the outer portion for load carrying capability.

Abstract: An engine block assembly includes an engine block casting including a plurality of cylinder bores disposed in series, each cylinder having a cylinder wall. Outer engine block walls are peripheral to the cylinder walls. A channel is formed between outer peripheral surfaces of the cylinder walls and the outer engine block walls. A coolant passage fluidly connects through the outer block walls to the channel. A water jacket insert includes an upper flange, a strut portion and a lower flange. A plurality of orifices are formed in the strut portion. A compressible seal attached to the lower flange of the water jacket insert, which is assembled into the channel and conforms to a bottom portion of the channel.

Abstract: A composite accumulator includes a base having a closed end and an open end, the base having an inner surface that defines a cavity and having a fluid port in communication with the cavity for communicating a hydraulic fluid in and out of the cavity. A cover is disposed over the open end of the base and is secured to the base by a fastener. A piston is disposed within the base and the cover. The piston is sealed to the inner surface of the cover and is translatable along an axis. A biasing member is disposed within the base and the cover and located axially between the piston and the cover. The base and the cover are plastic.

Abstract: An assembly clip for holding together a stationary hydraulic lash adjuster (SHLA) and a roller finger follower (RFF) in a valve train of an internal combustion engine (ICE) is provided. The SHLA has a pivot, and the RFF has a pivot cap configured to fit around the pivot. The assembly clip includes a first attachment section and a second attachment section configured to engage with the pivot cap and pivot, respectively, to attach the assembly clip to the RFF and SHLA, respectively. When assembled, the pivot and the pivot end are substantially located between the first attachment section and the second attachment section, the pivot cap covering at least a portion of the pivot. The assembly clip is made of an oil soluble material such that it may dissolve and break away after the valve train is assembled into the ICE, and the assembly clip no longer serves a function.

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 assembly clip for holding together a stationary hydraulic lash adjuster (SHLA) and a roller finger follower (RFF) in a valve train of an internal combustion engine (ICE) is provided. The SHLA has a pivot, and the RFF has a pivot cap configured to fit around the pivot. The assembly clip includes a first attachment section and a second attachment section configured to engage with the pivot cap and pivot, respectively, to attach the assembly clip to the RFF and SHLA, respectively. When assembled, the pivot and the pivot end are substantially located between the first attachment section and the second attachment section, the pivot cap covering at least a portion of the pivot. The assembly clip is made of an oil soluble material such that it may dissolve and break away after the valve train is assembled into the ICE, and the assembly clip no longer serves a function.

Abstract: A shaft assembly includes a shaft, a spacer and a cover. The body of the shaft includes a sealing portion, a balancing portion and a hollow portion which may collectively define a generally cylindrical space. The spacer substantially encloses the hollow portion of the body. The cover encapsulates the shaft body and the spacer to provide a substantially continuous cylindrical surface in sealing engagement with the sealing portion. The shaft assembly may be rotatably installed in an engine such that the balancing portion may be partially submerged in an oil bath in the engine and such that the substantially continuous cylindrical surface of the cover minimizes turbulence and aeration of the oil bath when the shaft assembly is rotated. The shaft may be configured for rotation in synchrony with a crankshaft. A method for encapsulating the shaft includes forming a continuous cylindrical surface in sealing engagement with the shaft body.

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: A composite accumulator includes a base having a closed end and an open end, the base having an inner surface that defines a cavity and having a fluid port in communication with the cavity for communicating a hydraulic fluid in and out of the cavity. A cover is disposed over the open end of the base and is secured to the base by a fastener. A piston is disposed within the base and the cover. The piston is sealed to the inner surface of the cover and is translatable along an axis. A biasing member is disposed within the base and the cover and located axially between the piston and the cover. The base and the cover are plastic.

Abstract: An engine assembly may include a camshaft rotationally supported on an engine structure. The camshaft may include a first shaft, a second shaft located in and rotatable relative to the first shaft and a partial cam lobe located on the first shaft. The partial cam lobe may include a peak region and may define a partial bore. A radial distance defined by the partial bore between first and second circumferential ends of the partial bore may be greater than or equal to a radial width of the first shaft. The partial cam lobe may define a recess extending in a radial direction through the partial bore and into the partial cam lobe. The camshaft may include a sleeve located within a radial passage defined by the second shaft and the recess in the partial cam lobe and radially locating the partial cam lobe relative to the second shaft.

Abstract: A method of assembling a camshaft may include locating a first lobe member of the camshaft on a first shaft and inserting a locking pin into a first bore in the first lobe member and into a second bore in the first shaft. The locking pin may include a first recess extending into a first end thereof defining a first annular wall. A first retaining member may be forced into a first recess. The forcing may displace the annular wall in an outward radial direction and into a frictional engagement with the first bore.

Abstract: A shaft assembly includes a shaft, a spacer and a cover. The body of the shaft includes a sealing portion, a balancing portion and a hollow portion which may collectively define a generally cylindrical space. The spacer substantially encloses the hollow portion of the body. The cover encapsulates the shaft body and the spacer to provide a substantially continuous cylindrical surface in sealing engagement with the sealing portion. The shaft assembly may be rotatably installed in an engine such that the balancing portion may be partially submerged in an oil bath in the engine and such that the substantially continuous cylindrical surface of the cover minimizes turbulence and aeration of the oil bath when the shaft assembly is rotated. The shaft may be configured for rotation in synchrony with a crankshaft. A method for encapsulating the shaft includes forming a continuous cylindrical surface in sealing engagement with the shaft body.