Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A steel piston with an engineered coating is provided. A high thermal conductivity material, for example copper, is disposed on first regions of a combustion bowl to reduce hot spots in the piston. A low thermal conductivity material, for example a ceramic, is disposed on second regions of the combustion bowl to reduce loss of heat through the piston. The high thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 5 ?m to help reflect IR radiation and promote fuel flow. The low thermal conductivity material disposed on the combustion bowl has a surface roughness (Ra) of less than 3 ?m to promote fuel flow. The low thermal conductivity material is also disposed on the bowl rim and top ring land, and has a surface roughness (Ra) of greater than 8 ?m on the bowl rim and top ring land to retard gas flow.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material can be applied first, followed by a mixture of the metal bond material and a ceramic material, optionally followed by a layer of the ceramic material. The ceramic material preferably includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material can be applied first, followed by a mixture of the metal bond material and a ceramic material, optionally followed by a layer of the ceramic material. The ceramic material preferably includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A steel piston for coupling to a connecting rod and wrist pin is provided. The piston includes a body with an upper crown presenting a combustion surface for exposure to a combustion chamber. The upper crown presents an undercrown surface which is openly exposed as viewed from an underside of the piston and not bounded by a cooling gallery. The body includes a ring belt and pin bosses depending from the ring belt and presenting a pin bore for receiving the wrist pin. The body also includes ribs disposed along the undercrown surface. The body includes a ratio of compression height to outer diameter (CH/D) ranging from 34.8% to 42.0%. The piston also includes a low heat transfer coating on the combustion surface, and the low heat transfer coating has a thermal conductivity of about 0.20 to 0.80 W/m·K.

Abstract: A piston for a diesel engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. A layer of a metal bond material is first applied to a combustion surface of the crown, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by a thermal spray process or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., based on the total volume of the thermal barrier coating, a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material is first applied, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A piston for an internal combustion engine and method of construction thereof are provided. The piston includes an upper crown formed at least in part by a first metal material and a thermally insulating insert. The upper crown has an upper wall forming an upper combustion surface and a ring belt region. The upper combustion surface is formed at least in part by the thermally insulating insert. The thermally insulating insert has a base surface with pores extending upwardly therein. The first metal material is infused and solidified in the pores, with the first metal material forming a first bonding surface. The piston further includes a body portion formed from a second metal material. The body portion provides pin bosses having coaxially aligned pin bores and diametrically opposite skirt portions. The body portion has a second bonding surface bonded to the first bonding surface of the first metal material.

Abstract: A steel piston for coupling to a connecting rod and wrist pin is provided. The piston includes a body with an upper crown presenting a combustion surface for exposure to a combustion chamber. The upper crown presents an undercrown surface which is openly exposed as viewed from an underside of the piston and not bounded by a cooling gallery. The body includes a ring belt and pin bosses depending from the ring belt and presenting a pin bore for receiving the wrist pin. The body also includes ribs disposed along the undercrown surface. The body includes a ratio of compression height to outer diameter (CH/D) ranging from 34.8% to 42.0%. The piston also includes a low heat transfer coating on the combustion surface, and the low heat transfer coating has a thermal conductivity of about 0.20 to 0.80 W/m·K.

Abstract: A piston ring includes a body portion presenting a running surface, and a spring member disposed between the body portion and a ring groove of a piston. A running surface of the piston ring presents an upper rail, a lower rail, and a fulcrum disposed between the rails and each extending radially outwardly. An outermost tip of the fulcrum is disposed radially outwardly relative to an outermost surface of the rails, and the running surface presents a convex shape along the fulcrum. The fulcrum contacts an oil film applied to a cylinder wall as the piston reciprocates along the cylinder wall. The spring member presses the body portion of the piston ring toward the cylinder wall and causes the body portion to pivot about the fulcrum to provide for improved control of the oil film, less friction, and reduced oil consumption.

Abstract: A piston for an internal combustion engine and method of construction thereof are provided. The piston includes an upper crown formed at least in part by a first metal material and a thermally insulating insert. The upper crown has an upper wall forming an upper combustion surface and a ring belt region. The upper combustion surface is formed at least in part by the thermally insulating insert. The thermally insulating insert has a base surface with pores extending upwardly therein. The first metal material is infused and solidified in the pores, with the first metal material forming a first bonding surface. The piston further includes a body portion formed from a second metal material. The body portion provides pin bosses having coaxially aligned pin bores and diametrically opposite skirt portions. The body portion has a second bonding surface bonded to the first bonding surface of the first metal material.

Abstract: A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m·K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

Abstract: A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material is first applied, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.

Abstract: A piston for a diesel engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. A layer of a metal bond material is first applied to a combustion surface of the crown, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by a thermal spray process or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., based on the total volume of the thermal barrier coating, a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m·K.