Engine with cylinder liner with bonding layer
AssigneeFederal-Mogul Corporation
InventorEric Allan Highum
Life of this patent
Estimating the term…
Abstract
A cylinder liner for an engine block assembly of an internal combustion engine is provided. The cylinder liner includes a liner member formed of cast iron and presenting an outer surface. A first portion of the outer surface of the liner member is machined to a reduced outside diameter. A material including aluminum is then thermally sprayed onto the machined first portion, while a second portion of the outer surface remains uncoated. The coated cylinder liner is then placed in a mold, and another material including aluminum is cast around the coated cylinder liner to form the engine block assembly. During the casting process, the two aluminum-containing materials form a strong intermetallic bond between the liner member and the engine block.
Claims20
A cylinder liner, comprising:
- a liner member having a length extending longitudinally from a top end to a bottom end;
- said liner member including an inside surface extending around a center axis and an oppositely facing outside surface;
- said outside surface presenting a first outside diameter along a first portion of said length and a second outside diameter along a second portion of said length, said first outside diameter being less than said second outside diameter;
- a bonding layer adhered to said outside surface along said first portion, and said bonding layer including aluminum.
A method of manufacturing a cylinder liner, comprising the steps of:
- providing a liner member having a length extending longitudinally from a top end to a bottom, the liner member including an inside surface extending around a center axis and an oppositely facing outside surface, the outside surface presenting a first outside diameter along a first portion of the length and a second outside diameter along a second portion of the length, and the first outside diameter being less than the second outside diameter;
- and
- adhering a bonding layer including aluminum to the outside surface of the liner member along the first portion of the length.
An engine block assembly, comprising:
- a plurality of cylinder liners, each cylinder liner including a liner member having a length extending longitudinally from a top end to a bottom end, said liner member including an inside surface extending around a center axis and an oppositely facing outside surface, said outside surface presenting a first outside diameter along a first portion of said length and a second outside diameter along a second portion of said length, and said first outside diameter being less than said second outside diameter;
- each of said cylinder liners including a bonding layer formed of a first material including aluminum applied to said outside surface along said first portion;
- a block formed of a second material including aluminum and presenting a plurality of bores each for receiving one of said cylinder liners;
- and
- said second material of said block being cast onto said first material of said bonding layers.
A method of manufacturing an engine block assembly, comprising the steps of:
- providing a plurality of cylinder liners, each cylinder liner including a liner member having a length extending longitudinally from a top end to a bottom end, the liner members each including an inside surface extending around a center axis and an oppositely facing outside surface, the outside surface presenting a first outside diameter along a first portion of the length and a second outside diameter along a second portion of the length, and the first outside diameter being less than the second outside diameter, each of the cylinder liners including a bonding layer of a first material including aluminum applied to the outside surface along the first portion;
- disposing the plurality of cylinder liners in a mold;
- and
- casting a second material including aluminum onto the bonding layers of the cylinder liners in the mold.
Dependencies are inferred from the claim text.