To provide a cast iron cylindrical member capable of improving the bonding strength when metal on the outer peripheral side and the cast iron cylindrical member are integrated. For this objective, in a cast iron cylindrical member including a plurality of projections including constricted projections on the outer peripheral surface, the anchor portion index (I) represented by {(A.sub.av.sup.2B.sub.av.sup.2)/4PnPr/100}0.35H/2 is set in a specific range.

A method for producing a cast aluminum component having at least one reinforcing element arranged therein includes producing a core by placing at least one reinforcing element in a first mold and at least partially overmolding the at least one reinforcing element with a foam material. In the alternative, or in addition to, a core is produced by surrounding an inner element composed of a foam material by at least one reinforcing element. The method includes placing the core in a second mold and pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

Methods and systems are provided for a turbine integrally formed with a cylinder head. In one example, a system includes a cylinder head and a turbine shaped from a single, continuous piece of metal.

An apparatus for a motor vehicle engine block made of aluminum includes an insert having a first surface and a second surface spaced apart from the first surface, the first surface being substantially flat, and a plurality of projections extending from the second surface, the plurality of projections being inserted into a portion of the engine block to secure the insert to the portion of the engine block. The first surface of the insert is configured to mate with another component, other than the engine block, made of steel or cast iron to avoid fatigue fretting of the aluminum engine block.

The present invention addresses the problem of providing a cylinder liner for insert casting, with which the bonding strength between a cylinder liner and a cylinder block can be improved by reducing voids generated on the cylinder block. The problem is solved by a cylinder liner for insert casting which includes plural projections on its outer peripheral surface and satisfies the following (i) and (ii): (i) the number of the projections is 5 to 50 per 1 cm.sup.2 on the outer peripheral surface, and (ii) when two 15.2 mm0.03 mm lines are set in parallel with a gap of 3.8 mm therebetween at an arbitrary position on the outer peripheral surface of the cylinder liner, the total number of projections that are in contact with the two lines is 8 or less.

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.

To provide a cast iron cylindrical member capable of improving the bonding strength when metal on the outer peripheral side and the cast iron cylindrical member are integrated. For this objective, in a cast iron cylindrical member including a plurality of projections including constricted projections on the outer peripheral surface, the anchor portion index (I) represented by {(A.sub.av.sup.2B.sub.av.sup.2)/4PnPr/100}0.35H/2 is set in a specific range.

A motor vehicle cylinder head is provided with a single flat planar surface in which are formed spaced apart integral inlet and outlet ports used for connecting respective coolant supply and returns to a coolant jacket defined within the cylinder head. The use of a common planar surface for the location of the inlet and outlet ports provides a more reliable sealing of the cylinder head to the respective coolant supply and returns.

A method for manufacturing a cylinder head includes: preparing a cylinder head casting having an intake passage, an exhaust passage, and a combustion chamber by casting using a mold and a plurality of cores; machining an intake port, an intake valve seat, an intake valve guide bore, an exhaust port, an exhaust valve seat, and an exhaust valve guide bore in the cylinder head casting by a first cylindrical tool; and forming a tapered surface on a portion of edge of the intake port by a second cylindrical tool. In particular, the second cylindrical tool moves along a predetermined trajectory at the edge portion of the intake port and rotates around an axis simultaneously to machine the tapered surface.

Methods and systems are provided for a turbine integrally formed with a cylinder head. In one example, a system includes a cylinder head and a turbine shaped from a single, continuous piece of metal.