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.

Provided are a method of manufacturing an engine, an engine, and a connected cylinder. The method of manufacturing an engine includes at least a fitting step of fitting a connected cylinder to a hollow portion of a cylinder block main body. The connected cylinder is (1) a first connected cylinder including two or more cylinder liners and a connecting portion configured to connect the two or more cylinder liners to each other or (2) a second connected cylinder including a connected cylinder main body portion having two or more cylinder bores and a coating configured to cover an inner peripheral surface of the connected cylinder main body portion in which the cylinder bores are formed. The cylinder block main body has one end side, another end side, and the hollow portion passing through the cylinder block main body from the one end side to the another end side.

There is provided an exhaust casing for a turbocharger that can be reduced in weight and can be easily machined. The exhaust casing (1) for the turbocharger includes an exhaust casing body (2) for the turbocharger that has a hollow structure and is made of a casting of iron-based metal, a light metal layer (3) that serves as an outer shell, and a heat insulating layer (4) that is provided between the exhaust casing body (2) and the light metal layer (3).

A cylinder head assembly for an internal combustion engine includes a cast cylinder head, a turbocharger housing integrally cast with the cylinder head, and a water jacket cast into the integrally cast turbocharger housing and configured to receive a flow of coolant for cooling the integrally cast turbocharger housing. The assembly can also include a wastegate housing integrally cast with the cylinder head and the turbocharger housing, and a water jacket cast into the integrally cast wastegate housing. The water jacket is configured to receive a flow of coolant for cooling the integrally cast turbocharger housing and the integrally cast wastegate housing.

A cylinder head assembly for an internal combustion engine includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head and having an integrally cast wastegate housing. The turbocharger housing is configured to receive a turbocharger cartridge rotatably supporting a shaft coupled between a compressor wheel and a turbine wheel. The integrally cast wastegate housing defines a wastegate chamber configured to receive a wastegate valve, a flow of exhaust gas from the turbine wheel, and a flow of wastegate exhaust gas.

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.

Methods and systems are provided for a sub-assembly. In one example, a method for the subassembly includes separating a monoblock of the subassembly into two separate portions and applying a sealing material to at least one of the two separate portions and rejoining the portions.

An engine assembly having an improved mounting system or assembly is disclosed. Features of this mounting system include having crankcase arms that are integrally formed with a crankcase of the engine assembly, having multiple mounting legs that each have a dedicated vibration damping subassembly and where the stiffness of at least two of the mounting legs is different (by varying the configurations of the corresponding vibration damping subassemblies), and using a mounting ring or base with having differently oriented mounting pads for securement of the corresponding mounting leg relative thereto.

A method of forming an assembly is provided. The method includes forming an insert, coating the insert with a bond material and placing the insert within a casting mold or die. The casting mold or die is purged with an inert gas and the casting mold or die is filled with molten metal to encapsulate the insert. The encapsulated insert is diffusion bonded to the molten metal to form a diffusion bonded insert, which is placed within a cavity of a secondary casting mold or die. The secondary casting mold or die is filled with molten metal to form a composite casting assembly. After or during the casting, the composite casting assembly is heat treated. In another method of the present disclosure, the insert includes ferrous alloys, nickel-based alloys, super alloys, and nonferrous alloys.

A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.