A ferritic aero diesel engine. The ferritic aero diesel engine includes an iron crankcase, a steel crankshaft and eight steel piston assemblies. The iron crankcase has a flat, horizontally opposed eight cylinder arrangement with a first set of cylinder walls defining a first set of cylinders in a first bank and a second set of cylinder walls defining a second set of cylinders in an opposed second bank. The steel crankshaft is rotatably mounted at least partially within the iron crankcase. Each of the steel piston assemblies of the plurality of steel piston assemblies is received within a respective cylinder of the iron crankcase and is coupled to the steel crankshaft. The first and second sets of cylinder walls have a minimum wall thickness of between approximately 4.8 and 5.2 mm.

A valve seat insert for an internal combustion engine has a first portion that is adapted to contact a cylinder head and a second portion that is adapted to contact a valve. The valve seat insert has a valve seat insert volume. A major part of the valve seat insert volume includes a homogeneous material that includes nitrides.

A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable salt core is located in each relief, the salt core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the salt core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable salt cores is also disclosed. The expendable salt cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.

A cylinder head assembly for an engine assembly is provided herein. The cylinder head assembly may include a head framework, an exhaust liner include a thermal barrier material, an intake liner, and a polymeric housing disposed around at least a portion of the metal head framework and the exhaust liner. The cylinder head assembly may further include a plurality of channels for heating and/or cooling the cylinder head assembly, which can be defined in one or more of: the metal head framework, the exhaust liner, and the polymeric housing. Methods of making the cylinder head assembly are also provided herein.

A cylinder head cover and a method for producing a cylinder head cover are disclosed. The method for producing a cylinder head cover may include: providing at least two metallic bearing bridges including a respective through-opening for mounting at least one camshaft and aligning the respective through-opening of the at least two bearing bridges axially relative to one another; connecting at least one metallic connection element to the at least two bearing bridges in a fixed manner so that the at least two bearing bridges are fixed and aligned relative to one another; and at least partially overmoulding the at least two bearing bridges and the at least one connection element with a plastic material.

The present disclosure relates to an internal combustion engine, in particular a reciprocating internal combustion engine, having at least one cylinder, wherein a cylinder wall of the cylinder is formed at least at a wall region forming a cylinder barrel by a coating of a crankcase or of a cylinder liner of the internal combustion engine by means of a coating material. According to the present disclosure, the coating material is formed of a high-alloy, steel alloy including, as alloying elements, chromium, nickel, copper and niobium.

An engine cylinder head includes an internal metal structure forming an upper portion of a combustion chamber. The internal metal structure includes a semi-compliant coating configured to absorb thermal expansion of the internal metal structure. The engine cylinder head also includes a polymer composite forming an external structure at least partially surrounding the internal metal structure.

A plasma spraying method for coating a cylinder barrel of a cylinder crankcase of a reciprocating internal combustion engine. A coating method is provided, with the aid of which the formation of oxides is limited or oxide banding in the layer formation and thus negative influences are avoided due to oxidation outbreaks and microgroove formation are avoided. The coating is applied to the cylinder barrel of the cylinder crankcase at least partially using the following parameter combination: rotational speed: 600 to 800 revolutions/minute; sprayed material delivery rate: 80 to 180 grams/minute; and feed rate: 24 to 75 mm/s.

Methods of manufacturing vehicle assemblies, such as engine assemblies, are provided. The method includes arranging at least a first component in a mold, arranging a second component or a second component precursor adjacent to the first component in the mold, introducing a sacrificial material into the mold, introducing at least one polymeric fluid into the mold, solidifying the polymeric fluid, and removing the sacrificial material from the mold to form a void space so that the first component, the polymeric composite material, and the void space define the vehicle assembly.

An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.