Federal-mogul Corporation

Tenneco Gmbh

Federal-mogul World Wide, Inc.

Federal-mogul Ignition Company

Federal-mogul Powertrain LLC

Miguel Azevedo

Warran Boyd Lineton

Keith Hampton

Michael Weinenger

Greg Salenbien

Gregory Salenbien

Matthew Belford

Carmo Ribeiro

Alan S Brown

Andrew Leibold

Geoffrey Neil Ainsworth

Xilou Zhu

Walter Joseph Griffiths

Eduardo Matsuo

James Robert Toth

Airton Martins

Jeffrey L Riffe

Thomas Egerer

William Zdeblick

Kai Wang

Eric Allan Highum

Jose Rebello

Tom Bedwell

Benjamin Louis Johnson

Neil Ainsworth

Kevin Hart

Andrew Stockwell

Geoffrey N Ainsworth

Eric Highum

A heavy duty piston for an internal combustion engine comprises a thermally conductive composition filling 10 to 90 vol. % of a sealed cooling gallery. The thermally conductive composition includes bismuth and/or tin. For example, the thermally conductive composition can be a single-phase binary mixture of bismuth and tin. The thermally conductive composition has improved thermal properties, for example a melting point around 139&#xb0; C., a thermal conductivity around 22 W/m&#xb7;K, and a thermal diffusivity around 1.43E-5 m/s. The thermally conductive composition is not reactive and does not include toxic or cost-prohibitive metals. During high temperature operation, as the piston reciprocates in the cylinder bore, the thermally conductive composition flows throughout the cooling gallery to dissipate heat away from the upper crown and thus improve efficiency of the engine.

Piston with sealed cooling gallery containing a thermally conductive composition

A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material can be applied first, followed by a mixture of the metal bond material and a ceramic material, optionally followed by a layer of the ceramic material. The ceramic material preferably includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m&#xb7;K.

Thermally insulated engine components using a ceramic coating

A steel piston with anti-coking design features is provided. The piston includes an upper crown portion and a lower crown portion forming an outer cooling gallery therebetween. The outer cooling gallery is substantially closed except for an oil inlet, oil outlet, and optional oil passage(s) to a central cooling gallery. According to one embodiment, at least one anti-coking insert is disposed in the outer cooling gallery and sized to prevent escaping through the oil inlet or the oil outlet. For example, the insert(s) can comprise a helical coil, a plurality of steel balls, coil springs, or chips formed of polymer with abrasive filler. Alternatively, an outer gallery floor to the outer cooling gallery includes a plurality of anti-coking openings disposed sequentially in decreasing spaced relation from one another, or anti-coking openings with varying lengths.

Piston with anti-coking design features

A piston for an internal combustion engine is provided. The piston includes a body having a cylindrical outer surface with a ring belt region including an annular uppermost ring groove and a lower ring groove extending into the outer surface. A top land extends from the uppermost ring groove to an upper combustion surface. The body has a pair of pin bosses with pin bores aligned with one another along a pin bore axis. A first piston ring is disposed in the uppermost ring groove and a second piston ring is disposed in the lower ring groove. The body has an annular sealed cooling gallery with a cooling medium contained therein. The sealed cooling gallery is configured in substantial radial alignment between the first and second piston rings to provide optimal cooling to the ring belt region, top land and upper combustion surface.

Piston with enhanced cooling gallery

A vehicle internal combustion piston and method of construction thereof are provided. The piston includes piston body extending along a central longitudinal axis, having an upper combustion wall forming an upper combustion surface and an undercrown surface opposite the upper combustion surface. An annular ring belt region depends from the upper combustion surface, a pair of skirt panels depend from the ring belt region, and a pair of pin bosses depend from the undercrown surface to provide laterally spaced pin bores aligned along a pin bore axis for receipt of a wrist pin. The undercrown surface forms a central undercrown region, and a portion of either an open outer cooling gallery, a sealed outer cooling gallery, or an outer galleryless region. A coating including copper is applied to hot spots along the undercrown surface to mitigate the hot spots provide a more uniform temperature along the undercrown surface during operation.

Piston having an undercrown surface with coating and method of manufacture thereof

A steel piston for coupling to a connecting rod and wrist pin is provided. The piston includes a body with an upper crown presenting a combustion surface for exposure to a combustion chamber. The upper crown presents an undercrown surface which is openly exposed as viewed from an underside of the piston and not bounded by a cooling gallery. The body includes a ring belt and pin bosses depending from the ring belt and presenting a pin bore for receiving the wrist pin. The body also includes ribs disposed along the undercrown surface. The body includes a ratio of compression height to outer diameter (CH/D) ranging from 34.8% to 42.0%. The piston also includes a low heat transfer coating on the combustion surface, and the low heat transfer coating has a thermal conductivity of about 0.20 to 0.80 W/m&#xb7;K.

Galleryless short compression insulated steel piston

A piston for an internal combustion engine and method of construction is provided. The piston has a robust, lightweight monolithic piston body including an upper wall forming a combustion bowl depending radially inwardly from an annular, uppermost combustion surface. An undercrown surface is formed on an underside of the combustion bowl, with at least a portion of the undercrown surface being bounded by diametrically opposite skirt portions, pin bosses and strut portions connecting the skirt portions to the pin bosses. The bounded undercrown surface has an openly exposed surface area, as viewed looking along a central longitudinal axis along which the piston reciprocates, providing an expansive area against which oil being splashed or sprayed can come into direct contact with to enhance cooling the piston while in use. Through channels extending over upper regions of the pin bosses can be provided to further reduce weight and facilitate cooling.

Robust, lightweight, low compression height piston and method of construction thereof

A piston for a diesel engine is provided. The piston includes a thermal barrier coating applied to a crown formed of steel. A layer of a metal bond material is first applied to a combustion surface of the crown, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by a thermal spray process or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., based on the total volume of the thermal barrier coating, a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m&#xb7;K.

Thermally insulated steel piston crown and method of making using a ceramic coating

A component for exposure to a combustion chamber of a diesel engine and/or exhaust gas, such as a cylinder liner or valve face, is provided. The component includes a thermal barrier coating applied to a body portion formed of steel. A layer of a metal bond material is first applied, followed by a gradient structure including a mixture of the metal bond material and a ceramic material, followed by a layer of the ceramic material. The ceramic material includes at least one of ceria, ceria stabilized zirconia, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating is applied by thermal spray or HVOF. The thermal barrier coating has a porosity of 2% by vol. to 25% vol., a thickness of less than 1 mm, and a thermal conductivity of less than 1.00 W/m&#xb7;K.

Thermally insulated engine components and method of making using a ceramic coating

A piston assembly, piston therefor and methods of construction are provided. The assembly includes a piston head and connecting rod operably coupled thereto via a wrist pin. The piston head has an upper crown with a combustion bowl and an undercrown surface. The lower crown includes axially aligned pin bores receiving the wrist pin. An upper wall of the lower crown has an oil inlet, an oil outlet and a concave, saddle bearing surface that bears against the wrist pin. A toroid-shaped outer cooling gallery is formed between wall portions of the upper and lower crowns, wherein the outer cooling gallery surrounds an inner cooling gallery. The connecting rod is fixed to the wrist pin for conjoint oscillation. The connecting rod has an oil passage in fluid communication with a through hole in the wrist pin to allow oil to flow therethrough into the inner cooling gallery via the oil inlet.

Reduced compression height dual gallery piston, piston assembly therewith and methods of construction thereof

A piston for an internal combustion engine and method of construction thereof are provided. The piston includes an upper crown formed at least in part by a first metal material and a thermally insulating insert. The upper crown has an upper wall forming an upper combustion surface and a ring belt region. The upper combustion surface is formed at least in part by the thermally insulating insert. The thermally insulating insert has a base surface with pores extending upwardly therein. The first metal material is infused and solidified in the pores, with the first metal material forming a first bonding surface. The piston further includes a body portion formed from a second metal material. The body portion provides pin bosses having coaxially aligned pin bores and diametrically opposite skirt portions. The body portion has a second bonding surface bonded to the first bonding surface of the first metal material.

Piston with thermally insulating insert and method of construction thereof

A power cylinder assembly for an internal combustion engine includes a cylinder wall that surrounds a cylinder bore that extends along an axis. A piston assembly is positioned in the cylinder bore, and the piston assembly has a combustion surface that divides the cylinder bore into a combustion chamber on one axial side of the combustion surface and a crank case on an opposite axial side of the combustion surface. The combustion surface is partially defined by a first upper surface of a first piece and partially defined by a second upper surface of a second piece. The second piece is moveable relative to the piston body during operation of the power cylinder assembly to change a compression ratio of the power cylinder assembly.

Isobaric piston assembly

A piston for an internal combustion engine and method of construction thereof is provided. The piston has a piston body including an upper part and a lower part. The upper part has an upper combustion surface configured for direct exposure to combustion gases within a cylinder bore with an undercrown surface beneath the upper combustion surface. The body has a ring belt region configured for receipt of at least one piston ring adjacent the upper combustion surface with an annular cooling gallery configured radially inwardly from the ring belt region. The cooling gallery has a floor, wherein the floor has at least one through opening. A coolant medium is disposed in the cooling gallery, and a sealing member is disposed in the at least one through opening to seal off the coolant medium in the coolant gallery.

Piston with sealed cooling gallery and method of construction thereof

A steel piston for heavy-duty diesel engines designed with features that increase adiabaticity, reduce weight, and improve passive cooling without loss of power density is provided. The piston includes a pair of skirt walls extending longitudinally from a crown to a lower end. The skirt walls include a plurality of heat sink wells extending axially from the crown to a lower end of the skirt wall. Each heat sink well is at least partially filled with a cooling medium and is sealed. The piston also includes a plurality of ribs each radially aligned with one of the heat sink wells and extending inwardly and upwardly from a first rib end at an inner surface of the skirt wall to a second rib end at the inner surface of the crown.

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Ann Arbor, MI, United States of America

Miguel Azevedo