Engine block and cylinder liner assembly and method

A method of installing and securing a cylindrical liner in a cylinder bore of an internal combustion engine block, said method comprising:

• a) providing a metallic liner having a cylindrical inner surface and a cylindrical outer surface;
• b) applying a metallic bonding layer on the outer cylindrical surface of the liner to metallurgically unite with the liner material to provide intermetallic compounds, wherein the metallic bonding layer has as a major constituent on a weight basis a bonding metal having a melting temperature substantially lower than the melting temperatures of the engine block and of the liner, wherein the bonding metal is capable of forming alloys with each of the engine block material and the liner material;
• c) providing an aluminum alloy engine block having at least one cylindrical bore;
• d) applying a bonding layer of the metallic bonding layer material to the cylindrical bore to provide a metallurgically bonded coating having intermetallic compounds therein;
• e) heating the liner and engine block to a temperature near the melting point of the bonding metal sufficient to soften or melt the bonding layer on the liner and on the cylindrical bore of the block;
• f) pressing the heated liner into the bore in the heated block to cause fracturing of surface oxides of the bonding metal at the interface between the liner and the cylinder bore to metallurgically join the liner to the bore.