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 core is located in each relief, the expendable core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the expendable 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 cores is also disclosed. The expendable 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 block of an engine is provided. The cylinder block includes a cast body defining one or more cylindrical bores. The cylinder block also includes a crankshaft bearing wall formed within the cast body. The crankshaft bearing wall is configured to be removably coupled with a bearing cap to define an opening for rotatably supporting a crankshaft of the engine. The cylinder block further includes a chamfered shoulder portion casted on the crankshaft bearing wall.

Various systems and methods are provided for reducing an amount of oil reaching a crankcase overpressure sensor. In one example, a system may include a cast wall protruding perpendicularly from an internal wall of crankcase, the cast wall at least partially surrounding a sensor port for a crankcase overpressure (COP) sensor, the sensor port fluidically coupled to the COP sensor via an internal passage; and a cover plate fixedly coupled to the cast wall, the cover plate parallel to the internal wall. In this way, oil may be blocked from reaching the COP sensor, while air may flow through the internal passage to the COP sensor.

A liner for a cylinder of an internal combustion engine can comprise a hollow cylindrical wall or body having an inner surface, an outer surface opposite the inner surface, and open top and bottom ends. The outer surface can be without any sealing grooves in at least a bottom portion thereof. A relatively thin portion of the wall or body can be provided below a thick portion of the wall or body, and may reach the bottom end of the wall or body. An angled transition can define a change in thickness from the thick portion to the thin portion.

An internal combustion engine is provided, including at least one cylinder head including a water pump that is cast into the cylinder head housing.

An automobile vehicle engine includes multiple water jackets individually formed in a cast engine block proximate to successive ones of multiple cylinder bores. Multiple cast-in place transition regions are individually formed during a casting operation of the cast engine block at entrances to individual ones of the multiple water jackets. Individual ones of multiple sawcuts open into individual ones of the multiple cast-in place transition regions.

Various systems and methods are provided for reducing an amount of oil reaching a crankcase overpressure sensor. In one example, a system may include a cast wall protruding perpendicularly from an internal wall of crankcase, the cast wall at least partially surrounding a sensor port for a crankcase overpressure (COP) sensor, the sensor port fluidically coupled to the COP sensor via an internal passage; and a cover plate fixedly coupled to the cast wall, the cover plate parallel to the internal wall. In this way, oil may be blocked from reaching the COP sensor, while air may flow through the internal passage to the COP sensor.

A system for making a hybrid cam bore sand core with metal chills for an engine block includes an engine block cast of an aluminum material. A camshaft bore extends through the engine block. A cam bore sand core with at least one metal chill is positioned within the camshaft bore. A body portion of the at least one metal chill is positioned in direct contact with a cam bearing surface of at least one cam bearing member during casting of the engine block to increase a cooling rate of the at least one cam bearing member and create a crystalline material depth of the cam bearing member having enhanced mechanical properties.

An arrangement for converting thermal energy from lost heat of an internal combustion engine into mechanical energy where a working circuit is provided for a working medium which can be heated and evaporated using the lost heat. An expansion machine for obtaining mechanical energy from the heat of the working medium is provided in the working circuit where the working circuit extends through a heat exchanger mounted upstream of the expansion engine in the flow direction of the working medium. The internal combustion engine includes a cylinder having a cylinder liner. A cooling duct is provided in the cylinder liner through which the working medium flows. The cylinder liner is formed by centrifugal casting where the cooling duct is introduced into one centrifugal mold as an insert prior to the centrifugal casting.

An engine block formed according to a method that includes forming an insert, coating the insert with a bond material, placing the insert within a casting mold or die, purging the casting mold or die with an inert gas, filling the casting mold or die with molten metal to encapsulate the insert, diffusion bonding the molten metal to the insert to form a diffusion bonded insert, placing the diffusion bonded insert within a cavity of a secondary casting mold or die, filling the secondary casting mold or die with molten metal to form an engine block composite casting assembly, and casting and heat treating the engine block composite casting assembly is provided. The insert can be free of serrations for mechanical coupling between the insert and the engine block.