The present invention relates to the technological field of cast iron alloys for automotive and similar applications. Problem to be solved: Presently, structural parts of internal combustion engines are made of gray cast iron alloys that rarely have a tensile strength limit range greater than 350 MPa or vermicular cast iron alloys that do not remain stable at high temperatures. Solution of the problem: It is disclosed a vermicular cast iron alloy that, due to the addition of amounts of Molybdenum, Copper and Tin, with Hot Resistance Factor from 0.5 to 1.7% (HRF=3×(% Mo)+1×(% Sn)+0.25×(% Cu)) achieves a tensile strength limit of 500 to 550 MPa at room temperature and up to 300° C., and a tensile strength limit of 430 to 450 MPa at 400° C.

The present invention provides an aluminum hybrid metal matrix composite including cerium and graphite. The aluminum-cerium intermetallic is stable at temperatures up to a melting point of aluminum and graphite provides in situ lubrication. This stability is advantageous in applications such as cylinder liners and other applications where strength and stiffness at elevated temperatures are required.

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.

A casting apparatus for a cylinder block prevents deformation of a core pin and a cast passage formed by the core pin due to impact of molten metal when casting. Embodiments include a first side mold having a first core pin, a second side mold having a second core pin, a third mold having a molten metal inlet, and a metal dowel. The molten metal inlet is disposed so the inflow direction of molten metal intersects the axial direction of the first and second core pins, which are butted against each other at mold clamping and constitute a core for forming a main gallery for lubricant. The metal dowel is disposed between the molten metal inlet and a butt portion between the first and second core pins so that the butt portion is covered by the metal dowel from the upstream side in the inflow direction of the molten metal.

A piston has a top surface composed of porous alumina. Top surface includes a first region and a second region. The first region includes a part or all of a region connecting to an outer periphery of the top surface. The second region is adjacent to the first region. The second region includes some or all of the region inside the top surface. The porous alumina formed on the second region is thinner than that formed on the first region. In a manufacturing method of a piston, first, a casting piston made of aluminum alloy is prepared. Then, a casting surface in a first region is removed, thereby a material surface is exposed. Then, anodization of the casting piston is performed, whereby a porous alumina is formed on the first and second regions.

An internal combustion engine includes a one-piece cylinder block casting, a flywheel supported for rotation at a front block end, and a back gear train supported for rotation at a back block end. Cast-in pump inlet and outlet passages are formed in the cylinder block casting and open in a pump mounting face at the back block end. An oil pump is clamped to the pump mounting face and includes a pump inlet and a pump outlet fluidly connected, respectively, to the cast-in pump inlet passage and the cast-in pump outlet passage.

The invention relates to a method for producing an engine component, in particular a piston for an internal combustion engine, wherein an aluminum alloy is cast in the gravity die casting process and wherein the aluminum alloy has 7 to <14.5 wt % silicon, >1.2 to ≤4 wt % nickel, >3.7 to <10 wt % copper, <1 wt % cobalt, 0.1 to 1.5 wt % magnesium, 0.1 to ≤0.7 wt % iron, 0.1 to ≤0.7 wt % manganese, >0.1 to <0.5 wt % zirconium, ≥0.1 to ≤0.3 wt % vanadium, 0.05 to 0.5 wt % titanium, and 0.004 to ≤0.05 wt % phosphorus as alloying elements and aluminum and unavoidable contaminants as the remainder. The aluminum alloy can optionally comprise beryllium, wherein the calcium content is limited to a low level. The invention further relates to an engine component, in particular a piston for an internal combustion engine, wherein the engine component is composed at least partially of an aluminum alloy, and to the use of an aluminum alloy to produce an engine component, in particular a piston of an internal combustion engine.

An internal combustion engine includes a one-piece cylinder block casting, a flywheel supported for rotation at a front block end, and a back gear train supported for rotation at a back block end. Cast-in pump inlet and outlet passages are formed in the cylinder block casting and open in a pump mounting face at the back block end. An oil pump is clamped to the pump mounting face and includes a pump inlet and a pump outlet fluidly connected, respectively, to the cast-in pump inlet passage and the cast-in pump outlet passage.

A casting apparatus for a cylinder block prevents deformation of a core pin and a cast passage formed by the core pin due to impact of molten metal when casting. Embodiments include a first side mold having a first core pin, a second side mold having a second core pin, a third mold having a molten metal inlet, and a metal dowel. The molten metal inlet is disposed so the inflow direction of molten metal intersects the axial direction of the first and second core pins, which are butted against each other at mold clamping and constitute a core for forming a main gallery for lubricant. The metal dowel is disposed between the molten metal inlet and a butt portion between the first and second core pins so that the butt portion is covered by the metal dowel from the upstream side in the inflow direction of the molten metal.

An internal combustion engine has a cylinder head having a cylinder roof defining first and second intake ports. The cylinder head supports a spark plug positioned between a central axis of the cylinder roof and a fuel injector. A combustion pre-chamber is connected to and extends outwardly from the roof. The pre-chamber encapsulates the spark plug, and is offset from the central axis and positioned between the central axis and the first and second intake ports. The pre-chamber defines an inlet aperture and an outlet aperture positioned along a spray streamline of the fuel injector, and defines first and second side apertures. Each side aperture is positioned adjacent to a respective one of the first and second intake ports. A method of operating an engine having a pre-chamber is also provided.