Abstract: A cylinder liner for an internal combustion diesel engine and corresponding method of construction and method of improving engine performance therewith has a cylindrical inner wall providing a bore extending along a central axis for reciprocation of a piston therein. The inner wall has an axial lower portion and an axial upper portion. The lower portion has a first diameter below a top-dead-center plane and the upper portion has a second diameter provided by a material formed as one piece with the inner wall, wherein the first diameter is greater than the second diameter.

Abstract: The invention provides a method for machining a work-piece. The method includes the step of disposing a surface of a work-piece and an electrode a predetermined distance apart. The method also includes the step of directing a flow of electrolyte between the surface and the electrode. The method also includes the step of applying a voltage across the surface and the electrode to machine the work-piece to generate a current. The method also includes the step of adding a first predetermined material to the flow of electrolyte to bind to the surface of the work-piece and leave a protective layer.

Abstract: A diesel engine piston assembly comprises a piston body having a top wall with a combustion bowl formed in the top wall and having a combustion bowl edge, an outer ring belt formed with a plurality of ring grooves including a top ring groove with an upper wall of the top ring groove and a top land portion of the ring belt disposed between the top ring groove and the top wall, a pair of pin bosses with aligned pin bores and a skirt; and a diamond dispersed chromium composite coating applied to at least the top wall, the combustion bowl edge, the top land portion and the upper wall of the top ring groove.

Abstract: A wet-style cylinder liner (16) for a diesel engine is provided with a surface texture (28) to combat the effects of cavitation-induced erosion. The surface texture (28) can be formed as a coating (30) of manganese phosphate applied about the outer surface (26) of the cylinder liner (16) within the coolant flow passage (20) of the engine. The manganese phosphate is applied in such a manner that a crystalline structure of 2–8 ?m average grain size, blocky in nature, clearly faceted, with no cauliflower-like formations and a discernable channel network surrounding the crystals is formed. This crystalline structure works with the natural adhesion and surface tension effects within the liquid coolant to create a stagnant fluid layer about the outer surface (26) of the cylinder liner (16). The stagnant fluid layer functions like a self-healing armor plate.

Abstract: A wet-style cylinder liner (16) for a diesel engine is provided with a surface texture (28) to combat the effects of cavitation-induced erosion. The surface texture (28) can be formed as a coating (30) of manganese phosphate applied about the outer surface (26) of the cylinder liner (16) within the coolant flow passage (20) of the engine. The manganese phosphate is applied in such a manner that a crystalline structure of 2-8 ?m average grain size, blocky in nature, clearly faceted, with no cauliflower-like formations and a discernable channel network surrounding the crystals is formed. This crystalline structure works with the natural adhesion and surface tension effects within the liquid coolant to create a stagnant fluid layer about the outer surface (26) of the cylinder liner (16). The stagnant fluid layer functions like a self-healing armor plate.

Abstract: A monobloc piston assembly includes a piston head having a combustion bowl found in an upper surface and a ring belt found with a plurality of ring grooves. An oil cooling gallery is formed in the piston head adjacent the combustion bowl and ring belt. A pair of pin bosses are formed with aligned pin bores and a piston skirt is formed as an immovable piece with the pin bosses. An oil drainage groove is formed below the ring grooves and includes at least one drain hole open to the interior of the piston skirt.

Abstract: A diesel engine is fitted with a thin-walled wet liner fabricated of steel. The liner has a hardness that is within 10-20 Rc of the hardness of the piston rings carried on a piston within the liner. The inner surface of the liner is manufactured with a TRD=5Rvk (100?Mr2) of between 30 and 400 ?m, and a compound liner thickness to bore diameter in the range of 1.5 to 4 percent.

Abstract: A ferrous cylinder liner for use in diesel engines having exhaust gas recirculation (EGR) is protected from corrosive attack from the EGR environment by first final machining the inner running surface of the liner and thereafter plating the finished inner surface with a thin, non-porous, continuous coating of chromium which serves as a barrier to the EGR gases. The liner is installed and used in its as-coated condition with no post-coating finishing of the coated surface.

Abstract: A piston assembly for heavy duty diesel engine applications comprises a piston having pin bosses formed with pin bores for the accommodations of a wrist pin. The wrist pin is fabricated of steel and is extendable through the small end bore of a steel connecting rod and the bores of the piston body for coupling the piston body to the connecting rod. In lieu of a conventional Cu—Pb—Sn bushing usually pressed into the small end bore, a coating of manganese phosphate is applied to either the pin or small end bore of the connecting rod and pin bosses to provide the necessary tribological properties therebetween. The porous coating absorbs and entraps lubricating oil, creating a still lubricant squeeze film between the steel running surfaces under heavy load.

Abstract: A ferrous cylinder liner for use in diesel engines having exhaust gas recirculation (EGR) is protected from corrosive attack from the EGR environment by first final machining the inner running surface of the liner and thereafter plating the finished inner surface with a thin, non-porous, continuous coating of chromium which serves as a barrier to the EGR gases. The liner is installed and used in its as-coated condition with no post-coating finishing of the coated surface.