Ford Global Technolgoies, LLC

Ford Motor Company Limited

Barry E Shepley

Christopher Kelly Palazzolo

Oludele Olusegun Popoola

Keith Raymond Bartle

Robert Edward Dejack

Patrick John Hilton

V Durga Nageswar Rao

John Edward Chancey

Robert E DeJack

Deborah R Pank

A masking for an engine block to be thermally sprayed with a coating includes a head deck mask portion adapted to engage a head deck of an engine block to prevent over-spray of a thermally sprayed coating on the head deck. The masking also includes a crankcase mask portion adapted to be disposed in a crankcase chamber of the engine block and engage a lower end of a cylinder bore cavity of the engine block to prevent over-spay of the thermally sprayed coating into the crankcase chamber.

Masking for engine blocks for thermally sprayed coatings and method of masking same

Masking for engine blocks for thermally sprayed coatings

A method of treating a light metal cylinder bore wall to adherently receive a thermally sprayed metallic coating, that comprises (a) honing the wall to produce a net cylinder shape surface by use of spiral overlapping cross-abrasions having certain peaks and valleys of the abrasions folded over and molded to create tears, folds and undercuts rendering a hook and ladder effect, the honing being carried out with the use of a machining coolant to prevent burnishing of the walls; (b) either concurrently or shortly after step (a), washing the honed surface with a hot alkaline solution comprising (i) a non-soaping aluminate forming agent (sodium xanthate) that produces a residue on the walls, and (ii) surfactants that facilitate wetting of the walls even when some steam bubbles may be present; (c) rinsing the washed surfaces without disturbing the residue; and (d) thermally spraying a metallic bond coat and top coat on the honed and washed surface to render adhesion between the coating and prepared surface that is at least 6000 psi.

Method of treating light metal cylinder bore walls to receive thermal

A method of preparing and coating cylindrical bore surfaces of an aluminum workpiece that comprises (a) inserting and rotationally reciprocally moving a plurality of honing elements against the bore surface with a pressure of at least 30 psi to effect a pattern of spiral overlapping abrasions on said surface, each element being constituted of multifaceted, irregular-shaped, abrasive particles (i.e., diamond or SiC) having a particle size of 30-1300 micrometers. The particles, when in contact with the surface, plow micro-sized, non-smooth and irregularly spaced grooves in the aluminum workpiece resulting in spiral peaks and valleys along the direction of movement of the particles, whereupon repeated reciprocation and rotation of the elements (i.e. 50-200 sfm) thereagainst results in overlapping grooves and cross-abrading of the prior peaks and valleys accompanied by a molding and folding over of certain of the peaks and valleys to create irregular, micro-sized tears, folds, and undercuts; and (b) thermally depositing wear resistant metallic particles onto the abraded surface to form a cohesive coating, said deposited particles migrating into the non-smooth grooves and into the irregular tears, folds, and undercuts during thermal deposition to increase the mechanical bond strength of the coating to the workpiece surface.

Method of preparing and coating aluminum bore surfaces

Apparatus (10) and a method for finishing a workpiece (12) are performed by a first spindle (24) that rotatably mounts a milling cutter (28) about a central axis A and a second spindle (32) also mounted on the support for rotation about the central axis A to mount a grinding wheel. The first spindle (24) has an annular shape that extends around the second (32), and the apparatus includes a drive (38) capable of rotating the first spindle (24) at a slower rate than the rotation of the second spindle (32) such that milling and grinding operations can be performed at effective speeds. An axial slide (40) mounts the first spindle (24) for rotation and for axial movement along the central axis with the second spindle (32) on which the grinding wheel (36) is mounted located within the annular support.

Apparatus and method for finishing a workpiece

A segmented broach bar for machining axially separated coaxial bearing bores contained within a component for an internal combustion engine includes axially separated pilot segments and axially separated broaching segments, with at least one of the pilot segments being positioned between a pair of broaching segments. A broach bar has a lead end which first engages the bearing bores, with the broaching and pilot segments having diameters which are sized progressively greater as the distance from the lead end increases, with the broach and pilot segments being sized such that each broach segment produces a bore diameter accommodating the immediately following pilot segment.

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Novi, MI, United States of America

Barry E Shepley