Abstract: A method of controlling deposition of material from at least one plasma transferred wire arc (PTWA) torch within at least one bore includes: directing a fluid through a duct; and directing the fluid through a number of cannons N disposed adjacent and downstream from the duct. The fluid is directed through the duct and N cannons and past the PTWA torch while the PTWA torch is spraying downstream from N?1 cannons.

Abstract: A machine or autonomous system includes a diagnostic controller and is configured to perform a method for monitoring health of a machine. The method includes monitoring a set of first electrical signals indicative of control of a motor of the machine while the machine is operated in a first autonomous mode, determining that an abnormal operating condition has occurred in response to the set of first electrical signals meeting a first criteria, having the machine operate in a test mode in response to the determination that the abnormal operating condition has occurred, monitoring a set of second electrical signals indicative of control of the motor during the test mode, and determining a fault condition in response to the set of second electrical signals meeting a second criteria.

Abstract: A device and related method for removing debris from a metal wire formed by a process utilizing a lubricant is provided. The device includes at least two segments forming a passage through which the wire passes, each having a leading edge for stripping debris from the wire, and a resilient member positioned around the at least two segments and applying a force to the segments sufficient to cause contact between the leading edges and at least the debris on the metal wire passing through the passage. The method broadly includes the steps of moving the metal wire through a passage formed by a plurality of segments, contacting the wire moving through the passage using a leading edge of each of the at least two segments, and applying a force to the at least two segments to cause contact between the leading edge of each of the at least two segments and at least the debris on the wire passing through the passage.

Abstract: Methods and systems are provided for filling surface pores of a cylinder inner surface coating with one or more fill materials to provide desired material and performance properties. In one example, a cylinder for an engine includes an inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease material deposit, and/or decrease run-in duration.

Abstract: A machine or autonomous system includes a diagnostic controller and is configured to perform a method for monitoring health of a machine. The method includes monitoring a set of first electrical signals indicative of control of a motor of the machine while the machine is operated in a first autonomous mode, determining that an abnormal operating condition has occurred in response to the set of first electrical signals meeting a first criteria, having the machine operate in a test mode in response to the determination that the abnormal operating condition has occurred, monitoring a set of second electrical signals indicative of control of the motor during the test mode, and determining a fault condition in response to the set of second electrical signals meeting a second criteria.

Abstract: Methods and systems are provided for filling surface pores of a cylinder inner surface coating with one or more fill materials to provide desired material and performance properties. In one example, a cylinder for an engine includes an inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease material deposit, and/or decrease run-in duration.

Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act as wells for lubricant.

Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act as wells for lubricant.

Abstract: A method of controlling deposition of material from at least one plasma transferred wire arc (PTWA) torch within at least one bore includes: directing a fluid through a duct; and directing the fluid through a number of cannons N disposed adjacent and downstream from the duct. The fluid is directed through the duct and N cannons and past the PTWA torch while the PTWA torch is spraying downstream from N?1 cannons.

Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act wells for lubricant.

Abstract: An apparatus for controlling deposition of material from a plasma transferred wire arc (PTWA) torch within a bore is provided. The apparatus includes a duct and a plurality of cannons. The duct includes a plurality of fluid passageways separated by cross-members. The plurality of cannons are disposed adjacent and downstream from the plurality of fluid passageways of the duct. The flow of fluid is simultaneously directed through all of the fluid passageways and the plurality of cannons and past the PTWA torch in the bore.

Abstract: A device and related method for removing debris from a metal wire formed by a process utilizing a lubricant is provided. The device includes at least two segments forming a passage through which the wire passes, each having a leading edge for stripping debris from the wire, and a resilient member positioned around the at least two segments and applying a force to the segments sufficient to cause contact between the leading edges and at least the debris on the metal wire passing through the passage. The method broadly includes the steps of moving the metal wire through a passage formed by a plurality of segments, contacting the wire moving through the passage using a leading edge of each of the at least two segments, and applying a force to the at least two segments to cause contact between the leading edge of each of the at least two segments and at least the debris on the wire passing through the passage.

Abstract: A device and related method for removing debris from a metal wire formed by a process utilizing a lubricant is provided. The device includes at least two segments forming a passage through which the wire passes, each having a leading edge for stripping debris from the wire, and a resilient member positioned around the at least two segments and applying a force to the segments sufficient to cause contact between the leading edges and the wire passing through the passage. The method broadly includes the steps of moving the metal wire through a passage formed by a plurality of segments, contacting the wire moving through the passage using a leading edge of each of the plurality of segments, and applying a force to the plurality of segments to cause contact between the leading edge of each of the plurality of segments and the wire passing through the passage.

Abstract: Methods of honing a surface are disclosed. The method may include spraying a coating having an initial average bulk porosity onto an engine bore wall and honing the coating to create an intermediate honed surface. The method may then include cleaning the intermediate honed surface and honing the intermediate honed surface with a cutting force of, for example, 110-130 kgf after the cleaning step. This may create a honed surface having an average porosity greater than the initial average bulk porosity. The methods may create a honed surface having a porosity that is more porous than the initially sprayed coating. The increased porosity of the honed surface may allow for increased oil retention in, for example, engine bores.

Abstract: An interpolated roughening cutting tool includes a body having at least first and second cutting elements coupled thereto. The first cutting element includes rectangular cutting teeth. The second cutting element includes non-rectangular cutting teeth. The first and second cutting elements are configured to create grooves in a surface that have a top portion with blunt edge surfaces.

Abstract: A method includes spraying a coating on to an engine bore surface, honing the coated surface to create a honed surface region, and cleaning the honed surface region to remove material from the surface pores. The honed surface region includes a plurality of surface pores and upper, middle, and lower regions. Cleaning the honed surface region produces upper, middle, and lower region surface porosities, with the middle region porosity being greater than at least one of the upper and lower porosities.

Abstract: A method includes spraying a coating on to an engine bore surface, honing the coated surface to create a honed surface region, and cleaning the honed surface region to remove material from the surface pores. The honed surface region includes a plurality of surface pores and upper, middle, and lower regions. Cleaning the honed surface region produces upper, middle, and lower region surface porosities, with the middle region porosity being greater than at least one of the upper and lower porosities.

Abstract: Tools and methods for forming modified mechanical roughening profiles are disclosed. In at least one embodiment, an engine block is provided including a body defining a cylinder bore having a bore surface. The bore surface may have defined therein a plurality of grooves extending from the bore surface and each groove may have a base and a top portion. The top portion may have opposing chamfered edges. The chamfered edges may be formed by a tool including at least one cutting element having triangular teeth and at least one cutting element having rectangular teeth. In another embodiment, a tool including at least one cutting element having curved teeth and at least one cutting element having rectangular teeth may be used to form grooves having a curved/radiused edge surface. The disclosed roughening profiles may reduce oxide growth when a coating is applied to the bore surface.

Abstract: An apparatus for controlling deposition of material from a plasma transferred wire arc (PTWA) torch within a bore is provided. The apparatus includes a duct and a plurality of cannons. The duct includes a plurality of fluid passageways separated by cross-members. The plurality of cannons are disposed adjacent and downstream from the plurality of fluid passageways of the duct. The flow of fluid is simultaneously directed through all of the fluid passageways and the plurality of cannons and past the PTWA torch in the bore.

Abstract: Tools and methods for forming modified mechanical roughening profiles are disclosed. In at least one embodiment, an engine block is provided including a body defining a cylinder bore having a bore surface. The bore surface may have defined therein a plurality of grooves extending from the bore surface and each groove may have a base and a top portion. The top portion may have opposing chamfered edges. The chamfered edges may be formed by a tool including at least one cutting element having triangular teeth and at least one cutting element having rectangular teeth. In another embodiment, a tool including at least one cutting element having curved teeth and at least one cutting element having rectangular teeth may be used to form grooves having a curved/radiused edge surface. The disclosed roughening profiles may reduce oxide growth when a coating is applied to the bore surface.