Abstract:
A multi-layer thermal barrier coating is provided that includes an insulating layer having an outer surface defining a plurality of crevices therein and a sealing layer bonded to the outer surface of the insulating layer. The sealing layer is substantially non-permeable and is configured to seal against the insulating layer. The sealing layer fills in at least a portion of the crevices. A method of forming a thermal barrier coating is also provided, which includes a step of providing a plurality of hollow round microstructures bonded together, each having a diameter in the range of 10 to 100 microns to create an insulating layer. The method further includes depositing a plurality of metal particles onto the insulating layer and heating the plurality of metal particles to form a substantially non-permeable sealing layer over the insulating layer.
Abstract:
An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.
Abstract:
A cylinder liner assembly includes an inner wear cylinder, a shell disposed radially outside of an outer surface of the inner wear cylinder, and a central layer disposed between the inner wear cylinder and the shell. The inner wear cylinder is a metal or ceramic, the central layer is a porous material, and the shell is a fiber reinforced polymer. The cylinder liner assembly may include a coolant passage disposed adjacent to the outer surface of the inner wear cylinder, between the inner wear cylinder and the shell. The coolant passage is operable to circulate a coolant therethrough for cooling the inner wear cylinder.
Abstract:
An internal combustion engine includes a component configured to be subjected to combustion gasses, the component includes a substrate presenting a surface and a coating applied to the surface of the substrate. The coating includes an insulating layer applied to the surface having a plurality of microspheres and a sealing layer bonded to the insulating layer and seals against the insulating layer.
Abstract:
An internal combustion engine includes a component configured to be subjected to combustion gasses, the component includes a substrate presenting a surface and a coating applied to the surface of the substrate. The coating includes an insulating layer applied to the surface having a plurality of microspheres and a sealing layer bonded to the insulating layer and seals against the insulating layer.
Abstract:
A metallic thermal barrier coating for a component includes an insulating layer having a plurality of metallic microspheres applied to a substrate. A second metallic non-permeable layer is bonded to the insulating layer such that the sealing layer seals against the insulating layer. A method for applying a thermal barrier coating to a component includes placing an insulating layer having a plurality of microspheres to a surface of the substrate of the component. A heat treatment is applied to the insulating layer. A second non-permeable layer is bonded to and seals against the insulating layer.
Abstract:
A single-shaft dual expansion internal combustion engine includes an engine block, a cylinder head, a single crankshaft, a control shaft and first, second and third multi-link connecting rod assemblies. First and second power cylinders and an expander cylinder are formed in the engine block. First and second power pistons are moveable in the first and second power cylinders and are connected to respective first and second crankpins of the crankshaft. An expander piston is moveable in the expander cylinder and is connected to a third crankpin of the crankshaft. First and second multi-link connecting rod assemblies are coupled to first and second swing arms of the control shaft. A third multi-link connecting rod assembly is coupled to a third swing arm of the control shaft.
Abstract:
A piston compound internal combustion engine is disclosed with an expander piston deactivation feature. A piston internal combustion engine is compounded with a secondary expander piston, where the expander piston extracts energy from the exhaust gases being expelled from the primary power pistons. The secondary expander piston can be deactivated and immobilized, or its stroke can be reduced, under low load conditions in order to reduce parasitic losses and over-expansion. Two mechanizations are disclosed for the secondary expander piston's coupling with the power pistons and crankshaft. Control strategies for activation and deactivation of the secondary expander piston are also disclosed.
Abstract:
A single-shaft dual expansion internal combustion engine includes an engine block, a cylinder head and a crankshaft. First and second power pistons are moveable in first and second power cylinders and are connected to first and second crankpins of the crankshaft. An expander piston is moveable in an expander cylinder and is connected via a multi-link connecting rod assembly to a third crankpin of the crankshaft. A first balance shaft is arranged in a first longitudinal opening in the engine block, and a second balance shaft is arranged in a second longitudinal opening in the engine block. The first and second balance shafts have first and second counterweight portions, respectively, and the crankshaft has a third counterweight portion causing an imbalance in the crankshaft.
Abstract:
Methods of joining components to form vehicle assemblies, such as engine assemblies, are provided. The methods include arranging a first component having a first channel defined therein in a mold, arranging a second component having a second channel defined therein in the mold, and aligning the first and second channel to define a pin-receiving channel. At least one polymeric composite pin is inserted into the pin-receiving channel thereby joining the first and second components, wherein an adhesive is disposed adjacent to at least a portion of the polymeric composite pin.