A spray coating film has a first spray coating film formed on a surface of an aluminum substrate and a second spray coating film formed on a surface of the first spray coating film. In the first spray coating film, an inorganic material with a layered crystalline structure is dispersed in a Ni-based alloy material, and an area ratio of the inorganic material is in a range from 40% to 80% relative to the sectional area of the first spray coating film. The second spray coating film is a porous film composed of ZrO.sub.2—SiO.sub.2 based ceramic containing 30% to 50% by mass of SiO.sub.2, and the second spray coating film has an area ratio of pores of 30% to 80% relative to the sectional area of the second spray coating film.

A spray coating film has a first spray coating film formed on a surface of an aluminum substrate and a second spray coating film formed on a surface of the first spray coating film. In the first spray coating film, an inorganic material with a layered crystalline structure is dispersed in a Ni-based alloy material, and an area ratio of the inorganic material is in a range from 40% to 80% relative to the sectional area of the first spray coating film. The second spray coating film is a porous film composed of ZrO.sub.2—SiO.sub.2 based ceramic containing 30% to 50% by mass of SiO.sub.2, and the second spray coating film has an area ratio of pores of 30% to 80% relative to the sectional area of the second spray coating film.

Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

An iron-based sprayed coating for coating a bore inner surface of a cylinder block for an internal combustion engine. A coating surface contains pits, its pit amount is within a range of 0.01% to 2.1%, and an average roughness Ra of this coating surface is within a range of 0.01 μm to 0.15 μm. The cylinder block for an internal combustion engine includes a bore having this iron-based sprayed coating on its inner surface, and a cylinder block body having the bore. A sliding mechanism for an internal combustion engine includes this cylinder block for an internal combustion engine and a piston slidable with the bore of this cylinder block. The piston has a piston ring, and the piston ring has a chromium coating, a chromium nitride coating, or a diamond-like carbon coating at a sliding part with the bore.

An iron-based sprayed coating for coating a bore inner surface of a cylinder block for an internal combustion engine. A coating surface contains pits, its pit amount is within a range of 0.01% to 2.1%, and an average roughness Ra of this coating surface is within a range of 0.01 μm to 0.15 μm. The cylinder block for an internal combustion engine includes a bore having this iron-based sprayed coating on its inner surface, and a cylinder block body having the bore. A sliding mechanism for an internal combustion engine includes this cylinder block for an internal combustion engine and a piston slidable with the bore of this cylinder block. The piston has a piston ring, and the piston ring has a chromium coating, a chromium nitride coating, or a diamond-like carbon coating at a sliding part with the bore.

An example hydraulic system component of a machine includes a protective coating deposited by high velocity air fuel (HVAF) thermal spray, exhibiting high adhesion strengths and surface morphologies that promote lubricant adhesion and reduce the leakage of oil and/or hydraulic fluid from the hydraulic system. The coating may have surface roughness with Rz values less than 2 μm and hardness of 1000 Vickers or greater. The HVAF coating may be thinner than conventional coatings with thicknesses less than 100 μm. The HVAF coating may be deposited on a variety of steel components with adhesion strengths greater than those achieved by high velocity oxygen fuel (HVOF). The HVAF coating may be formed without time consuming roughening and/or post-grind operations, resulting in cost savings compared to conventional coatings. The coatings may have operational lifetimes of 1000 hours or more.

An example hydraulic system component of a machine includes a protective coating deposited by high velocity air fuel (HVAF) thermal spray, exhibiting high adhesion strengths and surface morphologies that promote lubricant adhesion and reduce the leakage of oil and/or hydraulic fluid from the hydraulic system. The coating may have surface roughness with Rz values less than 2 μm and hardness of 1000 Vickers or greater. The HVAF coating may be thinner than conventional coatings with thicknesses less than 100 μm. The HVAF coating may be deposited on a variety of steel components with adhesion strengths greater than those achieved by high velocity oxygen fuel (HVOF). The HVAF coating may be formed without time consuming roughening and/or post-grind operations, resulting in cost savings compared to conventional coatings. The coatings may have operational lifetimes of 1000 hours or more.

Disclosed are a cylinder liner for insert casting and a method for manufacturing the same. In particular, the cylinder liner for insert casting has cooling and warming performances suitable for functions of respective parts by imparting multiple layers having different thermal conductivity on the surface of the cylinder liner for insert casting, such that the cylinder liner can be used for vehicle cylinder blocks.

Disclosed are a cylinder liner for insert casting and a method for manufacturing the same. In particular, the cylinder liner for insert casting has cooling and warming performances suitable for functions of respective parts by imparting multiple layers having different thermal conductivity on the surface of the cylinder liner for insert casting, such that the cylinder liner can be used for vehicle cylinder blocks.

Polycrystalline material comprising a plurality of nano-grains of a crystalline phase of an iron group element and a plurality of crystalline grains of material including carbon (C) or nitrogen (N); each nano-grain having a mean size less than 10 nanometres.