Abstract: Processes for coating a ferrous or aluminum article, such as an engine cylinder liner insert, to provide a metallurgical bond with aluminum alloy material cast around the article. The article surface to be bonded is treated to remove impurities, oxides, and foreign materials, and the article is preheated. A molten metallic bonding material, such as zinc or a zinc alloy, is provided and the treated and preheated article is immersed in the bonding material to provide a metallurgically bonded coating on the surface of the article being treated. The coated article, either shortly after coating or, alternatively, after having been cooled to ambient temperature and stored, can then be placed in a mold and molten aluminum alloy poured around it to metallurgically bond the aluminum to the coating on the article. The resulting structure provides a metallurgical bond that has improved heat transfer characteristics and improved structural integrity.

Abstract: An engine block for an internal combustion engine including at least one bore, and a cylindrical liner that is pressed into the bore to define the inner cylindrical surface along which the piston reciprocates. The inner surface of the bore and the outer surface of the liner are each coated with a zinc or zinc alloy coating that is metallurgically bonded to the respective surfaces to form intermetallic bonds. The liner is pressed into the bore while the liner and bore are at an elevated temperature approximately corresponding to the melting temperature of zinc, in order to unite the liner and block by means of a metallurgical bond. The metallurgical bond is substantially continuous to provide a continuous metallic path for improved heat transfer and structural strength between the liner and the block material. The liner can be formed either from cast iron or from an aluminum alloy, and the engine block is preferably cast from an aluminum alloy.

Abstract: An aluminum-lithium based alloy which comprises 10-20 wt. % silicon, 1.5-5.0 wt. % copper, 1.0-4.0 wt. % lithium, 0.45-1.5 wt. % magnesium, 0.01-1.3 wt. % iron, 0.01-0.5 wt. % manganese, 0.01-1.5 wt. % nickel, 0.01-1.5 wt. % zinc, 0.01-0.5 wt. % silver, 0.01-0.25 wt. % titanium and the balance aluminum. The alloy is utilized to cast high temperature assemblies including pistons which have a reduction in density and similar mechanical properties including tensile strengths to alloys presently used.