Abstract:
An intermetallic bond between a ferrous metal and a non-ferrous metal wherein an intermetallic bond layer that is substantially free of graphic inclusions joins the two. The graphite is effectively eliminated from the bond layer by either removing it from the ferrous metal or by sealing it off from the bond layer. Graphite removal may be accomplished in a variety of ways, including electrochemical cleaning and laser surface treatment. Alternatively, the graphite may be prevented from incursing into the bond region by sealing it off with a layer of metal, such as a chromium plating, that prevents it from penetrating through the bond layer and into the non-ferrous metal.
Abstract:
In one form, a turbocharger component, such as a compressor wheel or an impeller, formed of a cast material or a material made using a powder metal process, includes a surface having at least a portion thereof treated by a thermo-mechanical treatment process, such as friction stir processing. At the treated portion, the material forming the component includes a microstructure that is different than the microstructure of the material throughout the rest of the component. For example, in one form the material at the treated portion includes a homogenous microstructure while the material throughout the rest of the component includes a cast microstructure. In one or more forms, the treated portion exhibits at least one of increased strength, ductility and fatigue-resistant properties. In another form, a method is directed to providing components for a turbocharger which exhibit enhanced structural properties. However, other embodiments, forms and applications are also envisioned.
Abstract:
A steel alloy with unique and superior combinations of properties such as elevated temperature strength, oxidation resistance, thermal conductivity and wear resistance. Disclosed embodiments comprise or substantially consist of: C in an amount of 0.2-0.45 weight %; Si in an amount of 0.6-1.1 weight %; Mn in an amount of ≤1.1 weight %; Cr in an amount of 2.5-4.0 weight %; one or both of Mo or W, a combined amount of the Mo or W≤0.9 weight %; Ti in an amount of 0.035-0.14 weight %; V in an amount of 0.18-1.1 weight % and the balance being Fe and usual impurities.
Abstract:
A fuel pump for pressurizing fuel and transporting the pressurized fuel to a common rail of an automotive engine is disclosed. The inner surface regions are processed by laser shock peening so that the fuel pump can provide a highly pressurized fuel to the common rail. The fuel pump includes an inlet check valve bore fluidly connected to a dome, the dome is fluidly connected to an outlet check valve bore, and the outlet check valve bore is fluidly connected to an outer check valve seat. A fuel-side surface of the fuel pump has a laser shock peened surface. The laser shock peened surface includes one or more of the fuel-side surface(s) of the inlet check valve bore, the dome, the outlet check valve bore, and/or the outlet check valve seat.
Abstract:
A reinforcing insert for an engine block formed of an engine block material is provided which is positioned in the bearing saddle area of the block for increasing the strength and stiffness of the bearing saddle area to ensure a secure connection of the main bearing cap throughout engine operation thereby ensuring proper crankshaft support and operation. The reinforcing insert is formed of a material having a higher modulus of elasticity than a modulus of elasticity of the engine block material. The insert includes a lower transverse surface for positioning at a lowermost position in the engine block, an upper surface positioned farthest from the crankshaft, a first and second linear side surfaces for positioning on opposite sides of the crankshaft. The linear sides extend from the lower surface along respective planes in nonparallel relation to each other. The linear sides may extend either in a converging or a diverging manner from the lower surface. Alternatively, the insert may include two cylindrical inserts positioned in bores formed in the block on opposite sides of the crankshaft. These insert designs provide strengthening and stiffening of the block over an optimum area while permitting secure attachment of a main bearing cap to the block.
Abstract:
A combustion face insert is provided for connection to a bottom wall of an aluminum cylinder head adjacent a combustion chamber in an internal combustion engine which includes an insert body formed of a material having a predetermined hardness. The insert body includes a lower surface facing the combustion chamber and extending radially outwardly to form an outer peripheral extent having a predetermined size necessary to cause the lower surface to be positioned for engagement with an annular combustion seal to effectively seal the combustion chamber. This design allows a greater power density to be achieved in a heavy duty diesel engine utilizing an aluminum cylinder head, increases the thermal fatigue resistance of the valve bridge area and increases the resistance of an aluminum cylinder head to indentation by the combustion seal of the head gasket during deflection of the aluminum cylinder head. Hardened valve seats, which include either a hardened portion of the insert body or a hardened valve seat insert connected to the insert body, are positioned around intake and exhaust openings formed in the insert body for sealing abutment by respective intake and exhaust valves.
Abstract:
A reinforcing insert for an engine block formed of a lightweight material is provided which is positioned in the bearing saddle area of the block for increasing the strength and stiffness of the bearing saddle area to ensure a secure connection of the main bearing cap throughout engine operation thereby ensuring proper crankshaft support and operation. The reinforcing insert is formed of a material having a higher modulus of elasticity than a modulus of elasticity of the lightweight engine block material. The insert includes a lower transverse surface for positioning at a lowermost position in the engine block, an upper surface positioned farthest from the crankshaft, a first and second linear side surfaces for positioning on opposite sides of the crankshaft. The linear sides extend from the lower surface along respective planes in nonparallel relation to each other. The linear sides may extend either in a converging or a diverging manner from the lower surface. Alternatively, the insert may include two cylindrical inserts positioned in bores formed in the block on opposite sides of the crankshaft. These insert designs provide strengthening and stiffening of the block over an optimum area while permitting secure attachment of a main bearing cap to the lightweight block.