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: A piston compound internal combustion engine is disclosed with an expander piston deactivation feature. A piston internal combustion engine is compounded with a secondary expander piston, where the expander piston extracts energy from the exhaust gases being expelled from the primary power pistons. The secondary expander piston can be deactivated and immobilized, or its stroke can be reduced, under low load conditions in order to reduce parasitic losses and over-expansion. Two mechanizations are disclosed for the secondary expander piston's coupling with the power pistons and crankshaft. Control strategies for activation and deactivation of the secondary expander piston are also disclosed. In addition, six-cylinder engine configurations are defined by replicating groups of two power pistons and one expander piston.

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: 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: 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: 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: 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: 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: 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: 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: A single-shaft dual expansion internal combustion engine is described, and includes an engine block including first and second power cylinders and an expander cylinder fluidly coupled through a cylinder head, and first and second power pistons that connect to respective first and second crankpins of the crankshaft. A multi-link connecting rod assembly includes a rigid main arm extending orthogonally to a longitudinal axis of the crankshaft and supporting a first pivot pin, a second pivot pin and a third pivot pin. The first pivot pin connects via a connecting rod to an expander piston reciprocating in the third cylinder. A third crankpin of the crankshaft serves as the second pivot pin and has a throw that is located 180 degrees of rotation of the crankshaft from a throw of the first crankpin. The third pivot pin connects to a swing arm connected to the engine block.

Abstract: A single-shaft dual expansion internal combustion engine includes first and second power cylinders and an expander cylinder. The cylinder head fluidly couples the first and second power cylinders and the expander cylinder. First and second power pistons reciprocate in the first and second power cylinders and connect to a first crankpin of the crankshaft. A multi-link connecting rod assembly includes a rigid main arm supporting a first pivot pin, a second pivot pin and a third pivot pin. The first pivot pin connects to an expander piston reciprocating in the third cylinder. The third pivot pin couples to a first end of a swing arm, and a second end of the swing arm rotatably couples to a fourth pivot pin that couples to a distal end of a rotating arm that attaches to a rotating shaft coupled to rotation of the crankshaft.

Abstract: A single-shaft dual expansion internal combustion engine includes an engine block, a cylinder head and a crankshaft. First and second power pistons are moveable in first and second power cylinders and are connected to first and second crankpins of the crankshaft. An expander piston is moveable in an expander cylinder and is connected via a multi-link connecting rod assembly to a third crankpin of the crankshaft. A first balance shaft is arranged in a first longitudinal opening in the engine block, and a second balance shaft is arranged in a second longitudinal opening in the engine block. The first and second balance shafts have first and second counterweight portions, respectively, and the crankshaft has a third counterweight portion causing an imbalance in the crankshaft.

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: A single-shaft dual expansion internal combustion engine is described, and includes an engine block including first and second power cylinders and an expander cylinder fluidly coupled through a cylinder head, and first and second power pistons that connect to respective first and second crankpins of the crankshaft. A multi-link connecting rod assembly includes a rigid main arm extending orthogonally to a longitudinal axis of the crankshaft and supporting a first pivot pin, a second pivot pin and a third pivot pin. The first pivot pin connects via a connecting rod to an expander piston reciprocating in the third cylinder. A third crankpin of the crankshaft serves as the second pivot pin and has a throw that is located 180 degrees of rotation of the crankshaft from a throw of the first crankpin. The third pivot pin connects to a swing arm connected to the engine block.

Abstract: A single-shaft dual expansion internal combustion engine includes first and second power cylinders and an expander cylinder. The cylinder head fluidly couples the first and second power cylinders and the expander cylinder. First and second power pistons reciprocate in the first and second power cylinders and connect to a first crankpin of the crankshaft. A multi-link connecting rod assembly includes a rigid main arm supporting a first pivot pin, a second pivot pin and a third pivot pin. The first pivot pin connects to an expander piston reciprocating in the third cylinder. The third pivot pin couples to a first end of a swing arm, and a second end of the swing arm rotatably couples to a fourth pivot pin that couples to a distal end of a rotating arm that attaches to a rotating shaft coupled to rotation of the crankshaft.

Abstract: A piston compound internal combustion engine is disclosed with an expander piston deactivation feature. A piston internal combustion engine is compounded with a secondary expander piston, where the expander piston extracts energy from the exhaust gases being expelled from the primary power pistons. The secondary expander piston can be deactivated and immobilized, or its stroke can be reduced, under low load conditions in order to reduce parasitic losses and over-expansion. Two mechanizations are disclosed for the secondary expander piston's coupling with the power pistons and crankshaft. Control strategies for activation and deactivation of the secondary expander piston are also disclosed. In addition, six-cylinder engine configurations are defined by replicating groups of two power pistons and one expander piston.

Abstract: A piston compound internal combustion engine is disclosed with an expander piston deactivation feature. A piston internal combustion engine is compounded with a secondary expander piston, where the expander piston extracts energy from the exhaust gases being expelled from the primary power pistons. The secondary expander piston can be deactivated and immobilized, or its stroke can be reduced, under low load conditions in order to reduce parasitic losses and over-expansion. Two mechanizations are disclosed for the secondary expander piston's coupling with the power pistons and crankshaft. Control strategies for activation and deactivation of the secondary expander piston are also disclosed.