Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.

Abstract: A hybrid ceramic/sand casting method of manufacturing a metal part. The method is especially suitable for manufacturing engine cylinder blocks or cylinder head, which have very small internal passages or other very small internal features. These parts are formed using a hybrid core having at least one ceramic section and at least one sand section, with the ceramic section being used to create the internal feature. A mold cavity is created for the part, and the hybrid core is positioned in the mold. Molten metal is introduced into the mold, and after the metal cools, the core is removed, thereby forming the part with the internal feature.

Abstract: A cylinder head for an engine is provided comprising a monolithic structure forming an upper deck, a fire deck, at least one coolant jacket and a cavity to accommodate a fuel injector or an ignitor therein, the cavity defined by a wall connecting the fire deck with the upper deck. The wall connecting the fire deck with the upper deck, as well as other features of the cylinder head, are preferably arranged to support the fire deck against a deflection thereof by transmitting a mechanical load introduced on a flame face of the fire deck to the upper deck. A method of increasing the stiffness of the cylinder head is also provided.

Abstract: A cylinder head sleeve for an engine is provided comprising a sleeve first part and a sleeve second part which form a cavity to contain a fuel injector or an ignitor, and wherein the sleeve first part and the sleeve second part which form a joint for the sleeve first part and the sleeve second part to move relative to each other. A cylinder head assembly is also provided comprising the sleeve and a cylinder head, as well as a method of providing the cylinder head assembly.

Abstract: A cylinder head for an engine is provided comprising a monolithic structure forming an upper deck, a fire deck, at least one coolant jacket and a cavity to accommodate a fuel injector or an ignitor therein, the cavity defined by a wall connecting the fire deck with the upper deck. The wall connecting the fire deck with the upper deck, as well as other features of the cylinder head, are preferably arranged to support the fire deck against a deflection thereof by transmitting a mechanical load introduced on a flame face of the fire deck to the upper deck. A method of increasing the stiffness of the cylinder head is also provided.

Abstract: A cylinder head sleeve for an engine is provided comprising a sleeve first part and a sleeve second part which form a cavity to contain a fuel injector or an ignitor, and wherein the sleeve first part and the sleeve second part which form a joint for the sleeve first part and the sleeve second part to move relative to each other. A cylinder head assembly is also provided comprising the sleeve and a cylinder head, as well as a method of providing the cylinder head assembly.

Abstract: An engine has a crankshaft. A compression piston within a compression cylinder is connected to the crankshaft such that the compression piston reciprocates through an intake stroke and a compression stroke. An expansion piston within an expansion cylinder is connected to the crankshaft such that the expansion piston reciprocates through an expansion stroke and an exhaust stroke. A crossover passage interconnects the compression and expansion cylinders. The crossover passage includes a crossover compression valve and a crossover expansion valve. A runner section is in a downstream portion of the crossover passage, and a helical end section is integrally connected to the runner section. The helical end section has a funnel spiraling about a valve stem of the crossover expansion valve. The funnel forces incoming air to rotate about the valve stem prior to entering the expansion cylinder to promote turbulent kinetic energy in the cylinder air/fuel charge.

Abstract: An engine has a crankshaft. A compression piston within a compression cylinder is connected to the crankshaft such that the compression piston reciprocates through an intake stroke and a compression stroke. An expansion piston within an expansion cylinder is connected to the crankshaft such that the expansion piston reciprocates through an expansion stroke and an exhaust stroke. A crossover passage interconnects the compression and expansion cylinders. The crossover passage includes a crossover compression valve and a crossover expansion valve. A runner section is in a downstream portion of the crossover passage, and a helical end section is integrally connected to the runner section. The helical end section has a funnel spiraling about a valve stem of the crossover expansion valve. The funnel forces incoming air to rotate about the valve stem prior to entering the expansion cylinder to promote turbulent kinetic energy in the cylinder air/fuel charge.