An apparatus for a combustion cylinder of a reciprocating piston engine includes a combustion cylinder end face component including a first side configured to face the combustion cylinder and extending in a radial direction of the combustion cylinder and a pocket recessed into the first side and including a recessed pocket surface. The combustion cylinder end face component may be one of a piston and a cylinder head. A thermal barrier coating is inlaid in the pocket. The thermal barrier coating includes a ceramic-metallic layer directly coating the recessed pocket surface and a ceramic layer directly coating the ceramic-metallic layer and including an outer surface facing the combustion cylinder.

An apparatus for a combustion cylinder of a reciprocating piston engine includes a combustion cylinder end face component including a first side configured to face the combustion cylinder and extending in a radial direction of the combustion cylinder and a pocket recessed into the first side and including a recessed pocket surface. The combustion cylinder end face component may be one of a piston and a cylinder head. A thermal barrier coating is inlaid in the pocket. The thermal barrier coating includes a ceramic-metallic layer directly coating the recessed pocket surface and a ceramic layer directly coating the ceramic-metallic layer and including an outer surface facing the combustion cylinder.

A piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

A piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

Improving an IC Engine’s thermal efficiency by heat preservation by providing: heat insulation layers to the cylinder, piston crown, combustion chamber and cylinder-head including internal gaps/cavities with or without vacuum; reduced carbonisation of fuel and oil; reduced the thermal shock by exhaust gas recirculation - EGR with control/intake valves, heating and storage tank; improved thermal shock resistance of insulation with flexible/porous thread/fibre and cloth materials bound together by binding with paste, stitching, weaving, braiding or pressed/clamped together; improved distortion resistance using sapphire or tungsten steel; an elongated piston cap or cone; segmented or annular sheet cylinder/liner construction; direct or indirect cooling of fuel injectors with fuel recirculation or spark plugs with high pressure gas jets in pits or slits.

Improving an IC Engine’s thermal efficiency by heat preservation by providing: heat insulation layers to the cylinder, piston crown, combustion chamber and cylinder-head including internal gaps/cavities with or without vacuum; reduced carbonisation of fuel and oil; reduced the thermal shock by exhaust gas recirculation - EGR with control/intake valves, heating and storage tank; improved thermal shock resistance of insulation with flexible/porous thread/fibre and cloth materials bound together by binding with paste, stitching, weaving, braiding or pressed/clamped together; improved distortion resistance using sapphire or tungsten steel; an elongated piston cap or cone; segmented or annular sheet cylinder/liner construction; direct or indirect cooling of fuel injectors with fuel recirculation or spark plugs with high pressure gas jets in pits or slits.

A thermal barrier coating for an internal combustion engine includes an insulating thermal spray coating, where a chosen material of the insulating thermal spray coating has a thermal conductivity lower than 2 W/mK in fully dense form and the chosen material includes a coefficient of thermal expansion within 5 ppm/K of a coefficient of thermal expansion of a material of a component of the internal combustion engine upon which the coating is placed.

A piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

A piston for an internal combustion engine which is coated for enhanced oxidation protection and/or erosion protection is provided. The piston includes a body formed of an iron-based material. The iron-based material is coated with a superalloy and manganese phosphate. The superalloy is preferably NiCrAlY, NiCrAl, NiCr, CoCrAly, and/or CoNiCrAlY. The manganese phosphate can be disposed on the superalloy, but not between the superalloy and the iron-based material. The superalloy preferably has a thickness of 0.1 to 2.0 mm, a porosity of 1% to less than 5%, and a surface roughness of less than 5 microns Ra. Another component for an internal combustion engine which is coated with the superalloy and the manganese phosphate is also provided.

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.