Abstract: An apparatus for a combustion cylinder of a reciprocating piston engine includes a combustion cylinder end face component including a first side configured to face the combustion cylinder and extending in a radial direction of the combustion cylinder and a pocket recessed into the first side and including a recessed pocket surface. The combustion cylinder end face component may be one of a piston and a cylinder head. A thermal barrier coating is inlaid in the pocket. The thermal barrier coating includes a ceramic-metallic layer directly coating the recessed pocket surface and a ceramic layer directly coating the ceramic-metallic layer and including an outer surface facing the combustion cylinder.

Abstract: A cylinder head includes novel designs for undercuts, contours of the outer enclosure, coolant jackets, and other cavities within an outer enclosure of the cylinder head. The cylinder head design enables the reduction of weight of the head while maintaining structural integrity of the head, and improves control of temperatures in intake side and exhaust side zones of the heads to improve operational efficiency of the engine. A method is provided for additive manufacturing of the cylinder head including the disclosed designs.

Abstract: A cylinder head includes novel designs for undercuts, contours of the outer enclosure, coolant jackets, and other cavities within an outer enclosure of the cylinder head. The cylinder head design enables the reduction of weight of the head while maintaining structural integrity of the head, and improves control of temperatures in intake side and exhaust side zones of the heads to improve operational efficiency of the engine. A method is provided for additive manufacturing of the cylinder head including the disclosed designs.

Abstract: A piston for a reciprocating piston engine includes a piston body including a piston form and a superalloy overlay cladding and metallurgically bonded with a portion of the piston form. The superalloy overlay includes a first weld layer disposed on the piston form which includes a first plurality of adjoining weld beads. The superalloy overlay further includes a second weld layer disposed on the first weld layer which includes a second plurality of adjoining weld beads.

Abstract: An apparatus for a combustion cylinder of a reciprocating piston engine includes a combustion cylinder end face component including a first side configured to face the combustion cylinder and extending in a radial direction of the combustion cylinder and a pocket recessed into the first side and including a recessed pocket surface. The combustion cylinder end face component may be one of a piston and a cylinder head. A thermal barrier coating is inlaid in the pocket. The thermal barrier coating includes a ceramic-metallic layer directly coating the recessed pocket surface and a ceramic layer directly coating the ceramic-metallic layer and including an outer surface facing the combustion cylinder.