A method for manufacturing a cylinder block for a vehicle integrates a cylinder liner with the cylinder block. The method includes steps of: preparing a molded material having a cylinder liner shape; fixing the prepared molded material to an inside of a mold for the cylinder block; and casting the cylinder block integrated with the molded material by injecting casting molten metal for the cylinder block into the mold for the cylinder block to which the molded material is fixed.

A cylinder liner for internal combustion engines has an outer roughened surface that has particularly good adherence properties. The surface has is covered with protrusions or spines of varying shapes and sizes, which are created by spraying the mold with a coating and then casting the cylinder liner in the mold. The spines are generally conical or needle-shaped, with the bases being larger than the tips. The spines have an aggregate cross-sectional surface area measured at 0.2 mm from a ground cylindrical surface that is between 50-90% of the total ground cylindrical surface area, and an aggregate cross-sectional surface area measured at 0.4 mm from the ground cylindrical surface that is between 20-45% of the total ground cylindrical surface area.

A robust engine assembly having reduced weight and efficient cooling, without an increase in fuel consumption or carbon dioxide emissions, is provided. The engine assembly includes a double-wall cylinder liner clamped between a cylinder head and a crankcase. A manifold is disposed along a portion of the cylinder liner and includes fluid ports aligned with fluid ports of the cylinder liner to convey cooling fluid to a cooling chamber located between the walls of the cylinder liner. For example, the manifold can be a low-loss hydraulic manifold cast integral with the crankcase. Tie rods connect the cylinder head to the crankcase to clamp the cylinder liner in position. Alternatively, the tie rods can be connected to a main bearing cradle located beneath the crankcase. No attachment features extend into the walls of the cylinder liner, which is especially advantageous when the cylinder liner is formed of aluminum.

In a method for manufacturing a cylinder block provided with cylinder bores, the cylinder block is held by a clamp device, stress is generated in the cylinder block by a holding force of the clamp device to duplicate deformations of the cylinder bores after assembling hearing caps thereon, boring is carried out with the cylinder bores deformed in a condition where the stress is generated, and a thermally sprayed coating is formed, after the boring, on each inner surfaces of the cylinder bores deformed in the condition where the stress is generated. According to the method for manufacturing a cylinder block, superior cylindricity, after assembling the bearing caps, of the cylinder bores on each of which the thermally sprayed coating is formed can be brought, and workability degradation of finishing works (honing) for each inner surface of the cylinder bores (thermally sprayed coatings) can be restricted.

In a method for manufacturing a cylinder block provided with cylinder bores, the cylinder block is held by a clamp device, stress is generated in the cylinder block by a holding force of the clamp device to duplicate deformations of the cylinder bores after assembling hearing caps thereon, boring is carried out with the cylinder bores deformed in a condition where the stress is generated, and a thermally sprayed coating is formed, after the boring, on each inner surfaces of the cylinder bores deformed in the condition where the stress is generated. According to the method for manufacturing a cylinder block, superior cylindricity, after assembling the bearing caps, of the cylinder bores on each of which the thermally sprayed coating is formed can be brought, and workability degradation of finishing works (honing) for each inner surface of the cylinder bores (thermally sprayed coatings) can be restricted.

Any one or more members of an engine, that is, a piston, a cylinder head and a valve, has a wall face disposed face-to-face to a combustion chamber, and the wall face is coated by a heat-insulation coating film. The heat-insulation coating film includes a heat-insulative layer formed on a surface of the wall face, and an inorganic-system coated-film layer formed on a surface of the heat-insulative layer. The heat-insulative layer includes a resin, and first hollow particles buried inside the resin and exhibiting an average particle diameter being smaller than a thickness of the heat-insulative layer. The inorganic-system coated-film layer includes an inorganic compound.

An internal combustion engine comprising: a combustion chamber surrounded by at least an inner wall of a cylinder bore, a cylinder head, a valve and a piston, and a coating layer arranged on at least part of the inner wall of the combustion chamber, wherein the thermal conductivity of the coating layer is, at room temperature, lower than the thermal conductivities of the cylinder block, the cylinder head, the valve and the piston, the thermal conductivity of the coating layer is reversibly increased along with a rise in the temperature of the coating layer, and wherein the heat capacity per unit area of the coating layer is more than 0 kJ/(m.sup.2.Math.K) and 4.2 kJ/(m.sup.2.Math.K) or less.

The invention relates to a cast iron material with lamellar graphite formation. It further relates to a motor vehicle part made of the cast iron material. In order to create a ferritic cast iron material having a higher thermal conductivity, it is proposed according to the invention that, in addition to Fe, the cast iron material contains 3.9 to 4.2 wt. % C, 0.3 to 0.9 wt. % Si and 2.0 to 7 wt. % Al. It has been demonstrated within the scope of the invention that not only the thermal conductivity but also the wear resistance and corrosion resistance of the material are increased in comparison to known cast iron materials.

A cylinder liner is disclosed. The cylinder liner may include a hollow generally cylindrical body extending from a top end to a bottom end along a longitudinal axis, and an annular flange extending radially outwardly from the top end of the body. The cylinder liner may also include an annular recess adjacent the flange at a side closest to the bottom end of the body. The recess may have first and second axial ends, a substantially straight portion extending between the first and second axial ends, and at least one fillet formed at an intersection between the straight portion and at least one of the first and second axial ends. A roll-burnishing operation may be performed on the straight portion and the at least one fillet in a direction along the longitudinal axis.

An imbedded control system is disclosed for use with an engine having a cylinder liner and a seal. The control system may have at least one sensor configured to generate a signal indicative of a combustion process occurring inside the cylinder liner, and a controller in communication with the sensor. The controller may be configured to determine an amount of heat generated inside the cylinder liner based on the signal and a combustion model of the engine, to determine a heat flux through the engine based on the amount of heat and a heat flux model of the engine, and to determine a temperature at the seal based on the heat flux and a thermal model of the cylinder liner. The controller may also be configured to track a time at the temperature, and to determine a damage count of the seal based on the time at the temperature.