Abstract: A charge-air cooler includes a reticulated foam element configured to provide a plurality of nonlinear flow paths for a relatively high-temperature first fluid. The charge-air cooler also includes a cooling passage element disposed one of proximate to and in direct contact with the reticulated foam element and configured to accept a relatively low-temperature second fluid. The charge-air cooler additionally includes a header element having a first connection configured to accept inflow of the second fluid to the cooling passage element and a second connection configured to facilitate outflow of the second fluid from the cooling passage element. Furthermore, the charge-air cooler includes a casing configured to house the reticulated foam element, the cooling passage element, and the header element. An internal combustion engine employing such a charge-air cooler is also disclosed.

Abstract: An air intake system for delivering induction air to a cylinder head of an internal combustion engine, including an intake plenum assembly mounted to an intake manifold, wherein the intake manifold is mounted to the cylinder head and an airflow cooler module mounted to the intake plenum. The air intake system also includes a throttle body and heat exchanger disposed in the airflow cooler module between an induction air inlet of the airflow cooler module and the intake plenum, wherein an induction air flow path extends from the induction air inlet, through the heat exchanger and the intake plenum to the cylinder head of the internal combustion engine.

Abstract: A charge-air cooler includes a reticulated foam element configured to provide a plurality of nonlinear flow paths for a relatively high-temperature first fluid. The charge-air cooler also includes a cooling passage element disposed one of proximate to and in direct contact with the reticulated foam element and configured to accept a relatively low-temperature second fluid. The charge-air cooler additionally includes a header element having a first connection configured to accept inflow of the second fluid to the cooling passage element and a second connection configured to facilitate outflow of the second fluid from the cooling passage element. Furthermore, the charge-air cooler includes a casing configured to house the reticulated foam element, the cooling passage element, and the header element. An internal combustion engine employing such a charge-air cooler is also disclosed.

Abstract: A friction-weld interface device for improving a structural strength of an assembly includes a first component having a concave tapered surface. The friction-weld interface also includes a second component having a convex tapered surface that is complementary to and is configured to receive the concave tapered surface of the first component. The assembly is formed by friction welding the concave tapered surface to the convex tapered surface. The friction-weld interface device may be used to assemble an air-intake manifold for an internal combustion engine, wherein the air-intake manifold is at least partially joined by the process of friction welding.

Abstract: A friction-weld interface device for improving a structural strength of an assembly includes a first component having a concave tapered surface. The friction-weld interface also includes a second component having a convex tapered surface that is complementary to and is configured to receive the concave tapered surface of the first component. The assembly is formed by friction welding the concave tapered surface to the convex tapered surface. The friction-weld interface device may be used to assemble an air-intake manifold for an internal combustion engine, wherein the air-intake manifold is at least partially joined by the process of friction welding.