Bore liner insert for cast engine block

A method of manufacturing a cylinder bore liner insert configured to be cast in an internal combustion engine block, the method comprising:

• performing an additive manufacturing process including:
• forming a liner wall having an inner surface, an outer surface, and an upper surface configured to be operably associated with a cylinder head, wherein the inner surface at least partially defines a cylinder bore configured to receive a piston therein;
• forming a liner water jacket internally within the liner wall, the liner water jacket at least partially surrounding the cylinder bore to provide cooling thereto via a flow of coolant within the liner water jacket;
• and
• forming a plurality of coolant ports in the upper surface, the plurality of coolant ports configured to enable flow of coolant between the liner water jacket and the cylinder head.

A cylinder bore liner insert configured to be cast in an internal combustion engine block, the cylinder bore liner insert comprising:

• a plurality of additive manufactured liner walls formed during an additive manufacturing process and each having an inner surface, an outer surface, and an upper surface configured to be operably associated with a cylinder head, wherein the inner surface at least partially defines a cylinder bore configured to receive a piston therein;
• a liner water jacket defined internally within the plurality of additive manufactured liner walls during the additive manufacturing process, the liner water jacket at least partially surrounding each cylinder bore to provide cooling thereto via a flow of coolant within the liner water jacket;
• a plurality of coolant ports formed in the upper surface and configured to enable flow of coolant between the liner water jacket and the cylinder head;
• wherein each additive manufactured liner wall includes a straight-walled cylindrical lower section and a bowl-like upper section, wherein the outer surface of the bowl-like upper section is curved to facilitate distributing casting forces experienced during the casting of the cylinder bore liner insert within the engine block;
• wherein the water jacket includes an interbore portion disposed within the additive manufactured liner walls between the conjoined cylinder bores to provide cooling therebetween;
• a first plurality of projections extending outwardly from the outer surface, the first plurality of projections formed integrally with the additive manufactured liner wall during the additive manufacturing process, wherein the first plurality of projections is configured to facilitate mechanically locking the cylinder bore liner insert during the casting of the cylinder bore liner insert within the engine block;
• a second plurality of projections extending inwardly from the inner surface into the cylinder bore, the second plurality of projections formed integrally with the additive manufactured liner wall during the additive manufacturing process;
• and
• a spray bore liner sprayed onto the inner surface and mechanically locked with the second plurality of projections.