A method of spray coating a substrate is disclosed, the method comprising: a step of spray coating metal particles onto a substrate; and a step of induction heating the coating; wherein the step of induction heating comprises performing the induction heating in a vacuum.

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 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.

An exhaust plenum chamber with a thermal barrier coating for an opposed-piston engine reduces heat rejection to coolant, while increasing exhaust temperatures, fuel efficiency, and quicker exhaust after-treatment light-off. The exhaust plenum chamber can include a coating on the inside surface of the chamber. Posts which are structural and provide cooling channels or passageways can be present in the exhaust plenum chamber and coated with the thermal barrier coating material.

A method for applying a thermal barrier coating (TBC) to a surface of a cast component includes providing a core, applying the TBC to the core to form a coated core, disposing the coated core within a casting mold, casting metal around at least a portion of the coated core to form a casting intermediary, and removing the core from the casting intermediary to form a cast component. The TBC includes hollow microspheres comprising metal, glass, and/or ceramic materials. The hollow microspheres can have an average diameter of about 10 m to about 100 m. The component can be an automotive component, such as an engine intake assembly, an engine exhaust manifold, an engine block, and/or an engine cylinder head. The surface of the cast component can be one or more surfaces which define an engine intake passage, an engine exhaust passage, and an engine combustion chamber.

A method for applying a thermal barrier coating (TBC) to a surface of a cast component includes providing a core, applying the TBC to the core to form a coated core, disposing the coated core within a casting mold, casting metal around at least a portion of the coated core to form a casting intermediary, and removing the core from the casting intermediary to form a cast component. The TBC includes hollow microspheres comprising metal, glass, and/or ceramic materials. The hollow microspheres can have an average diameter of about 10 m to about 100 m. The component can be an automotive component, such as an engine intake assembly, an engine exhaust manifold, an engine block, and/or an engine cylinder head. The surface of the cast component can be one or more surfaces which define an engine intake passage, an engine exhaust passage, and an engine combustion chamber.

Methods and systems are provided for an engine component assembly having one or more fastener retention apparatuses. In one example, a system may include each of the one or more fastener retention apparatuses including a rigid limiter and an integrated fastener retention feature adhered to an inner surface of an interior passage of the rigid limiter. Further, one or more fasteners may be held captive by each of the one or more fastener retention apparatuses capturing one fastener of the one or more fasteners.

Methods and systems are provided for an engine component assembly having one or more fastener retention apparatuses. In one example, a system may include each of the one or more fastener retention apparatuses including a rigid limiter and an integrated fastener retention feature adhered to an inner surface of an interior passage of the rigid limiter. Further, one or more fasteners may be held captive by each of the one or more fastener retention apparatuses capturing one fastener of the one or more fasteners.

A heat shielding film is formed on a surface wall constituting a combustion chamber. The heat shielding film includes a heat shielding layer and an oil repellent layer. The heat shield layer is formed on the wall surface. The heat shielding layer is composed of a material having thermal conductivity lower than base material of the combustion chamber. The oil repellent layer is formed on a surface of the heat shield layer. The oil repellent layer is composed of polyalkoxysiloxane. A contact angle of the oil repellent layer with engine oil is at least 40 degrees.

Provided are a silicate mixture and a combustion accelerator for increasing combustion efficiency in a combustion engine. The silicate mixture is formed by mixing a first component including one or two or more materials selected from silicon compounds including silicon, glass, and quartz, and a second component including one or two or more materials selected from materials formed by sintering a silicate mineral at a temperature of 1300 C. or higher and 2000 C. or lower and ores emitting a terahertz wave.