Reynolds Metals Company

Richard A Morley

William H Overbagh

John L Jorstad

George W Steele

Processes for coating a ferrous or aluminum article, such as an engine cylinder liner insert, to provide a metallurgical bond with aluminum alloy material cast around the article. The article surface to be bonded is treated to remove impurities, oxides, and foreign materials, and the article is preheated. A molten metallic bonding material, such as zinc or a zinc alloy, is provided and the treated and preheated article is immersed in the bonding material to provide a metallurgically bonded coating on the surface of the article being treated. The coated article, either shortly after coating or, alternatively, after having been cooled to ambient temperature and stored, can then be placed in a mold and molten aluminum alloy poured around it to metallurgically bond the aluminum to the coating on the article. The resulting structure provides a metallurgical bond that has improved heat transfer characteristics and improved structural integrity. The invention also provides improved assemblies having metallurgically bonded components, such as an engine block having metallurgically bonded cylinder liners.

Process for creation of metallurgically bonded inserts cast-in-place in

An aluminum-lithium based alloy which comprises 10-20 wt. % silicon, 1.5-5.0 wt. % copper, 1.0-4.0 wt. % lithium, 0.45-1.5 wt. % magnesium, 0.01-1.3 wt. % iron, 0.01-0.5 wt. % manganese, 0.01-1.5 wt. % nickel, 0.01-1.5 wt. % zinc, 0.01-0.5 wt. % silver, 0.01-0.25 wt. % titanium and the balance aluminum. The alloy is utilized to cast high temperature assemblies including pistons which have a reduction in density and similar mechanical properties including tensile strengths to alloys presently used.

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Chesterfield, VA, United States of America

Richard A Morley