A component for an engine is provided. The component includes a thermal barrier coating applied to a body portion formed of metal, such as steel or another ferrous or iron-based material. According to one embodiment, a bond layer of a metal is applied to the body portion, followed by a mixed layer of metal and ceramic with a gradient structure, and then optionally a top layer of metal. The thermal barrier coating can also include a ceramic layer between the mixed layer and top layer, or as the outermost layer. The ceramic includes at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide. The thermal barrier coating can be applied by thermal spray. The thermal barrier coating preferably has a thickness less than 200 microns and a surface roughness Ra of not greater than 3 microns.

A method for producing an internal combustion engine, includes the steps of providing a cylinder comprising a cylinder wall, wherein a surface of the cylinder wall has a structure which is designed and formed such that it can be penetrated by a coating; generating at least one barrier region by way of at least regional machining of the structure such that the coating cannot penetrate into the structure; and applying a coating to the cylinder wall, which coating does not penetrate into the structure in the at least one barrier region.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A manufacturing method for a cylinder head is described. A masking member is attached to a cylinder head material, which followed by a film formation step. The masking member comprises a mask portion to mask the matching surface with the cylinder block, mask portions to mask each of the openings of intake and exhaust ports and a mask portion to mask at least one narrow region sandwiched between openings of two adjacent port holes and has the shortest distance between opening edges of the two adjacent port holes. All Mask portions are coplanar and linked directly to each other.

A method for mounting a valve seat ring on a cylinder head of an internal combustion engine includes providing a valve seat ring, which has a ring height, and which is measured along an axial direction. The valve seat ring includes a support portion made of a support material and a functional portion made of a functional material. The valve seat ring is arranged on the cylinder head and the support portion of the support material is at least partially removed, so that the ring height of the valve seat ring is reduced.

A piston crown for a piston of a pair of pistons in a two-stroke, opposed-piston, compression ignition combustion engine has a barrier layer and a conductive layer. The barrier layer at least partially surrounds a combustion chamber formed by the piston crown and an end surface of an opposing piston. The conductive layer connects the crown to the rest of the piston body. The barrier layer and the conductive layer are joined either through welding or through the fabrication process. Optionally, the piston crown includes an insulating layer between the barrier and conductive layers.

A method of manufacturing an engine piston may include performing upper-body formation for forming an upper body as an upper portion of a piston body by pressing a powder-type sintered material, performing lower-body formation for forming a lower body as a lower portion of the piston body by pressing a powder-type sintered material, performing bonding for forming the piston body by providing a brazing material between the upper body and the lower body and brazing the upper body and the lower body to each other while sintering a sintered material, performing machining for removing pores from the surface of the piston body by machining the surface, and performing heat treatment for forming a passive film by performing at least one of nitriding heat treatment or oxidation heat treatment on the surface of the piston body.

A tool insert includes first, second, and third teeth arranged on a surface of the tool insert. The first tooth is arranged at a proximal end of the tool insert surface and has an angled leading end and a first tooth height. The second tooth is spaced from the first tooth by a first distance along the surface of the tool insert and has a second tooth height greater than the first tooth height. The third tooth is spaced from the second tooth by a second distance along the surface of the tool insert and has an extending angled portion. The first tooth forms a first groove in a bore surface. The second tooth increases the depth of the first groove. The third tooth provides at least one micro-scratch to one of the first groove and the bore surface.

A second dynamic vibration absorber is higher in resonance frequency than a first dynamic vibration absorber. At least one of a ratio of a mass of a body of the first dynamic vibration absorber to a reciprocating inertial mass of the reciprocative rotation mechanism or a ratio of a mass of a body of the second dynamic vibration absorber to the reciprocating inertial mass of the reciprocative rotation mechanism is set such that a peak frequency of antiresonance occurring in a higher frequency region of the first dynamic vibration absorber than the resonance frequency of the first dynamic vibration absorber is substantially different from that of antiresonance occurring in a lower frequency region of the second dynamic vibration absorber than the resonance frequency of the second dynamic vibration absorber.

A cylinder head material of an engine is casted (Step S1). Next, the cylinder head material is machined (Step S2). Next, a heat shielding film is formed on a ceiling surface of the cylinder head material (Step S3). Next, the film thickness of the heat shielding film is measured (Step S4). Next, a rank of a piston to be combined with the ceiling surface is selected (Step S5). The rank of the piston selected in Step S5 is a rank according to depth of a cavity. Next, the rank of the piston selected in Step S5 is stamped on the cylinder head (Step S6).