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US 9,316,173 B2Granted
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. An aluminum-based material 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 aluminum-based material is cast around the coated cylinder liner to form the engine block assembly. During the casting process, the two aluminum-based materials form a strong intermetallic bond between the liner member and the engine block.
Claims18
A cylinder liner comprising,
- a liner member extending longitudinally from a top end to a bottom end and presenting a length between said top and bottom ends;
- 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;
- and
- a bonding layer formed of an aluminum-based material applied to said outside surface along said first portion,
- wherein said bonding layer of an aluminum-based material is applied to said outside surface by thermal spraying.
3 more elements
A method of manufacturing a cylinder liner, comprising the steps of:
- providing a liner member extending longitudinally from a top end to a bottom end and presenting a length between the top and bottom ends, 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
- applying a layer of an aluminum-based material to the outside surface along the first portion of the length, wherein the step of applying the layer of the aluminum-based material to the outside surface includes thermally spraying the aluminum-based material onto the outside surface.
An engine block assembly, comprising:
- a plurality of cylinder liners, each cylinder liner including a liner member extending longitudinally from a top end to a bottom end and presenting a length between said top and bottom ends, 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 layer of a first aluminum-based material applied to said outside surface along said first portion, wherein said layers of a first aluminum-based material are applied to said outside surfaces of said cylinder liners by thermal spraying;
- a block formed of a second aluminum-based material and presenting a plurality of bores each for receiving one of said cylinder liners;
- and
- said first aluminum-based material of said cylinder liners being bonded to said second aluminum-based material of said block.
2 more elements
An engine block assembly, comprising:
- a plurality of cylinder liners, each cylinder liner including a liner member extending longitudinally from a top end to a bottom end and presenting a length between said top and bottom ends, 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 layer of a first aluminum-based material applied to said outside surface along said first portion;
- a block formed of a second aluminum-based material and presenting a plurality of bores each for receiving one of said cylinder liners;
- and
- said first aluminum-based material of said cylinder liners being bonded to said second aluminum-based material of said block, wherein said block presents a cooling chamber spaced from each of said bores by said second aluminum-based material, said block includes an upper surface presenting a plurality of bridge areas, each bridge area is planar and located between adjacent bores, said block includes a plurality of cooling passages each extending from said cooling chamber and through a portion of said block between said bores for conveying cooling fluid from said cooling chamber.
2 more elements
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 extending longitudinally from a top end to a bottom end and presenting a length between the top and bottom ends, 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, each of the cylinder liners including a layer of a first aluminum-based material applied to the outside surface along the first portion;
- disposing the plurality of cylinder liners in a mold;
- and
- casting a second aluminum-based material around the plurality of cylinder liners in the mold.
1 more element
Dependencies are inferred from the claim text.