Spark plug with cooling features and method of manufacturing the same

A ground electrode for a spark plug, comprising:

• an electrode base having a plurality of laser deposition layers arranged one on top of another;
• and
• a cooling feature having an internal cooling passage and a heat conducting material, the internal cooling passage is filled with the heat conducting material and includes a heat input portion, a heat output portion, and a main passage portion;
• the heat input portion is connected to the main passage portion and extends to an area near a sparking surface;
• and
• the heat output portion is connected to the main passage portion and extends to an area near an attachment surface where the ground electrode attaches to a spark plug shell;
• wherein the plurality of laser deposition layers make up walls that define the internal cooling passage within the electrode base.

A process for manufacturing a ground electrode for a spark plug, the process comprises the steps of:

• forming an electrode base using an additive manufacturing process, the electrode base is formed layer-by-layer such that a plurality of laser deposition layers are arranged one on top of another and define an internal cooling passage;
• adding a heat conducting material to the internal cooling passage;
• heating the heat conducting material such that it at least partially melts and fills the internal cooling passage;
• and
• allowing the at least partially melted heat conducting material to solidify and form a metallic bond with walls of the internal cooling passage, wherein the internal cooling passage and the heat conducting material are part of a cooling feature for removing heat from an area near a sparking surface.