Abstract: A thermal barrier coating for a component includes an insulating layer applied to a surface of a substrate. The insulating layer comprises a plurality of ceramic microspheres. A sealing layer is bonded to the insulating layer. The sealing layer is non-permeable such that the sealing layer seals against the insulating layer. A method for applying a thermal barrier coating to a surface of a substrate of a component includes providing a plurality of ceramic microspheres and applying the plurality of ceramic microspheres to the surface of the substrate. At least one heat treatment is applied to the plurality of ceramic microspheres on the surface of the component to create an insulating layer on the surface of the substrate.

Abstract: An internal combustion engine includes a component configured to be subjected to combustion gasses, the component includes a substrate presenting a surface and a coating applied to the surface of the substrate. The coating includes an insulating layer applied to the surface having a plurality of microspheres and a sealing layer bonded to the insulating layer and seals against the insulating layer.

Abstract: A metallic thermal barrier coating for a component includes an insulating layer having a plurality of metallic microspheres applied to a substrate. A second metallic non-permeable layer is bonded to the insulating layer such that the sealing layer seals against the insulating layer. A method for applying a thermal barrier coating to a component includes placing an insulating layer having a plurality of microspheres to a surface of the substrate of the component. A heat treatment is applied to the insulating layer. A second non-permeable layer is bonded to and seals against the insulating layer.

Abstract: Engine assemblies and methods of heating and/or cooling the engine assemblies are provided. The engine assembly has a metal liner defining a cylindrical region for receiving a piston, a polymeric composite housing disposed around at least a portion of the exterior surface of the metal liner, and a metal cylinder head. The polymeric composite housing comprises a polymer and a plurality of reinforcing fibers and at least one of: a plurality of microchannels for receiving a heat transfer fluid for heating and/or cooling the engine assembly; and at least one wire for heating the engine assembly.

Abstract: Methods of manufacturing vehicle assemblies, such as engine assemblies, are provided. The method includes arranging at least a first component in a mold, arranging a second component or a second component precursor adjacent to the first component in the mold, introducing a sacrificial material into the mold, introducing at least one polymeric fluid into the mold, solidifying the polymeric fluid, and removing the sacrificial material from the mold to form a void space so that the first component, the polymeric composite material, and the void space define the vehicle assembly.

Abstract: Vehicle assemblies, such as engine assemblies, including an integrated cylinder head and plurality of liners as well as a polymeric composite housing are provided. Methods of making such vehicle assemblies are also provided.

Abstract: Methods of joining components to form vehicle assemblies, such as engine assemblies, are provided. The methods include arranging a first component having a first channel defined therein in a mold, arranging a second component having a second channel defined therein in the mold, and aligning the first and second channel to define a pin-receiving channel. At least one polymeric composite pin is inserted into the pin-receiving channel thereby joining the first and second components, wherein an adhesive is disposed adjacent to at least a portion of the polymeric composite pin.

Abstract: Crankshaft assemblies for vehicle assemblies, such as engine assemblies, and methods of manufacturing crankshaft assemblies are provided. The crankshaft assembly includes a first crankpin disposed between a first pair of webs and at least a first main bearing journal connected to the first pair of webs, wherein at least one of the first crankpin, the first pair of webs or the first main bearing journal is a polymeric composite including a polymer and a plurality of reinforcing fibers.

Abstract: A vehicle includes an engine having a combustion chamber with an inlet and an outlet. Valves and valve actuators regulate open and closing of the inlet and the outlet. A plasma ignition source initiates ignition in the combustion chamber. A controller is in communication with the inlet valve actuator and outlet valve actuator. The controller is configured to detect a transition from a first combustion mode of the engine to a second combustion mode of the engine. The controller is also configured to change at least one of an opening time, a closing time, and an open duration of the first valve in response to detecting the transition.

Abstract: A vehicle includes an engine having a combustion chamber with an inlet and an outlet. Valves and valve actuators regulate open and closing of the inlet and the outlet. A plasma ignition source initiates ignition in the combustion chamber. A controller is in communication with the inlet valve actuator and outlet valve actuator. The controller is configured to detect a transition from a first combustion mode of the engine to a second combustion mode of the engine. The controller is also configured to change at least one of an opening time, a closing time, and an open duration of the first valve in response to detecting the transition.

Abstract: An internal combustion engine is described and includes a combustion chamber formed by cooperation of a cylinder bore formed in a cylinder block, a cylinder head and a piston. A plasma ignition controller is electrically connected to a groundless barrier discharge plasma igniter that includes a tip portion disposed to protrude into the combustion chamber. A current sensor is disposed to monitor secondary current flow between the plasma ignition controller and the groundless barrier discharge plasma igniter. The plasma ignition controller is disposed to execute a plasma discharge event. A controller is disposed to monitor a magnitude of the secondary current flow via the current sensor during the plasma discharge event. The controller includes an instruction set executable to evaluate integrity of the groundless barrier discharge plasma igniter based upon the magnitude of the secondary current flow during the plasma discharge event.

Abstract: An internal combustion engine is configured to operate in a homogeneous-charge compression-ignition combustion mode. Operation of the engine includes determining a combustion pressure parameter for each cylinder. Fueling for each cylinder is controlled responsive to a target state for the combustion pressure parameter for the corresponding cylinder. An end-of-injection timing and a corresponding spark ignition timing for each cylinder are controlled responsive to a target mass-burn-fraction point for an engine operating point.

Abstract: An exhaust aftertreatment system for purifying an exhaust gas feedstream expelled from an internal combustion engine that is operable at an air/fuel ratio that is lean of stoichiometry is described. The exhaust aftertreatment system includes a plasma reactor disposed upstream of a selective catalytic reactor device. The plasma reactor is electrically connected to a plasma controller. The plasma controller controls the plasma reactor to generate ozone from constituents of the exhaust gas feedstream, and the ozone reacts to oxidize nitrogen oxide contained in the exhaust gas feedstream to form nitrogen dioxide. The nitrogen dioxide reacts with a reductant in the selective catalytic reactor device to form elemental nitrogen and water.

Abstract: An internal combustion engine is described and includes a combustion chamber formed by cooperation of a cylinder bore formed in a cylinder block, a cylinder head and a piston. A plasma ignition controller is electrically connected to a groundless barrier discharge plasma igniter that includes a tip portion disposed to protrude into the combustion chamber. A current sensor is disposed to monitor secondary current flow between the plasma ignition controller and the groundless barrier discharge plasma igniter. The plasma ignition controller is disposed to execute a plasma discharge event. A controller is disposed to monitor a magnitude of the secondary current flow via the current sensor during the plasma discharge event. The controller includes an instruction set executable to evaluate integrity of the groundless barrier discharge plasma igniter based upon the magnitude of the secondary current flow during the plasma discharge event.

Abstract: An exhaust aftertreatment system for purifying an exhaust gas feedstream that is expelled from an internal combustion engine that is operable at an air/fuel ratio that is lean of stoichiometry is described. The exhaust aftertreatment system includes a barrier discharge plasma reactor that is disposed upstream relative to a catalytic reactor and electrically connected to a plasma controller. The barrier discharge plasma reactor is controlled to generate ozone from constituents of the exhaust gas feedstream when the internal combustion engine is operating at a lean air/fuel ratio and at a low temperature condition. The generated ozone reacts, in the catalytic reactor, to oxidize non-methane hydrocarbons contained in the exhaust gas feedstream when the internal combustion engine is operating at lean air/fuel ratio and at low temperature conditions.

Abstract: A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

Abstract: An engine assembly includes an internal combustion engine with an engine block having at least one cylinder and at least one piston moveable within the at least one cylinder. A crankshaft is moveable to define a plurality of crank angles (CA) from a bore axis defined by the cylinder to a crank axis defined by the crankshaft. A controller is operatively connected to the internal combustion engine and configured to receive a torque request (TR). The controller is programmed to determine a desired combustion phasing (CAd) for controlling a torque output of the internal combustion engine. The desired combustion phasing is based at least partially on the torque request (TR) and a pressure-volume (PV) diagram of the at least one cylinder.

Abstract: An engine assembly includes an internal combustion engine with an engine block having at least one cylinder. An intake manifold and an exhaust manifold are each fluidly connected to the at least one cylinder and define an intake manifold pressure (pi) and an exhaust manifold pressure (pe), respectively. A controller is operatively connected to the internal combustion engine and configured to receive a torque request (TR). The controller is programmed to determine a desired fuel mass (mf) for controlling a torque output of the internal combustion engine. The desired fuel mass (mf) is based at least partially on the torque request (TR), the intake and exhaust manifold pressures and a pressure-volume (PV) diagram of the at least one cylinder.

Abstract: A single-shaft dual expansion internal combustion engine includes an engine block, a cylinder head, a single crankshaft, a control shaft and first, second and third multi-link connecting rod assemblies. First and second power cylinders and an expander cylinder are formed in the engine block. First and second power pistons are moveable in the first and second power cylinders and are connected to respective first and second crankpins of the crankshaft. An expander piston is moveable in the expander cylinder and is connected to a third crankpin of the crankshaft. First and second multi-link connecting rod assemblies are coupled to first and second swing arms of the control shaft. A third multi-link connecting rod assembly is coupled to a third swing arm of the control shaft.

Abstract: The method can control a powertrain in order to maintain the charge temperature at a desired value regardless of exhaust manifold pressure or altitude. The method includes the following steps: (a) receiving a torque request; (b) determining a desired air charge based, a least in part, on the torque request; (c) determining an actual air charge based, at least in part, on input signals from a manifold absolute pressure (MAP) sensor and a mass airflow (MAF) sensor; (d) adjusting an intake valve timing of the intake valve such that the actual air charge is equal to a desired air charge, and (e) adjusting throttle position and actuator positions of boosting devices such that the actual intake manifold pressure is equal to the desired intake manifold pressure.