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.

The present disclosure relates to a piston for an internal combustion engine. The piston comprises a cover which at least partially covers a piston basehead of the piston. A heat-isolating air gap is formed between the cover and the piston basehead, which is fluidically connected to a combustion chamber and/or an upper side of the cover facing away from the heat-isolating air gap. The fluidic connection permits a fluid exchange to take place between the heat-isolating air gap and the combustion chamber. In this way, a pressure gradient can be reduced between the combustion chamber and the heat-isolating air gap. As a result, the cover is/can be kept thin without being deformed during combustion.

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.

A combustion-chamber structure of an engine comprises a combustion chamber which is partitioned by a cylinder block, a cylinder head, and a piston. The piston includes a piston body having an upper surface facing the combustion chamber, a heat-insulation layer provided at least in a central area, in a radial direction, of the upper surface and having smaller heat conductivity than the piston body, a heat-barrier layer provided to cover the upper surface and having smaller heat conductivity than the piston body and the heat-insulation layer, and a heat-diffusion layer provided between the heat-insulation layer and the heat-barrier layer and having larger heat conductivity than the heat-insulation layer and the heat-barrier layer. The heat-diffusion layer comprises a side end edge and an extension portion which contact with the piston body.

A top surface of the piston includes a first region. A heat shielding film is formed on the first area. The top surface further includes a second region. There is no heat shielding film formed on the second region. Instead, the second area is mirror-finished. The top surface includes a central portion. A valve recess portion is formed on an intake side of the central portion. A squish portion is formed the intake side of the valve recess portion. The first area includes at least the central portion. The second area includes at least the squish portion.

A top surface of the piston includes a first region. A heat shielding film is formed on the first area. The top surface further includes a second region. There is no heat shielding film formed on the second region. Instead, the second area is mirror-finished. The top surface includes a central portion. A valve recess portion is formed on an intake side of the central portion. A squish portion is formed the intake side of the valve recess portion. The first area includes at least the central portion. The second area includes at least the squish portion.

A piston of an internal-combustion engine may include a piston head and a piston skirt, a cooling duct circulating in the piston head, a boss for receiving a piston pin, and a feed hopper for supplying cooling oil into the cooling duct. The feed hopper may be fastened to another component of the piston via a retaining lug by at least one of a material closure, a force closure, and a positive closure.

A piston of an internal-combustion engine may include a piston head and a piston skirt, a cooling duct circulating in the piston head, a boss for receiving a piston pin, and a feed hopper for supplying cooling oil into the cooling duct. The feed hopper may be fastened to another component of the piston via a retaining lug by at least one of a material closure, a force closure, and a positive closure.

A method of manufacturing an internal combustion engine is provided. The engine includes a cylinder forming member, a piston reciprocatably accommodated in a cylinder, an injector which supplies fuel into a combustion chamber, and a heat insulating layer covering at least a part of a combustion-chamber wall surface and having a lower heat conductivity than the combustion-chamber wall surface. The method includes applying a coating material that is a material of the heat insulating layer to the combustion-chamber wall surface, assembling the piston to the cylinder forming member while the coating material is uncured, and heating the coating material to be cured by combusting the fuel injected from the injector and reciprocating the piston. The heating the coating material includes injecting the fuel from the injector at least in an early stage of the heating so that the injected fuel adhering to the surface of the coating material is suppressed.

A method of manufacturing an internal combustion engine is provided. The engine includes a cylinder forming member, a piston reciprocatably accommodated in a cylinder, an injector which supplies fuel into a combustion chamber, and a heat insulating layer covering at least a part of a combustion-chamber wall surface and having a lower heat conductivity than the combustion-chamber wall surface. The method includes applying a coating material that is a material of the heat insulating layer to the combustion-chamber wall surface, assembling the piston to the cylinder forming member while the coating material is uncured, and heating the coating material to be cured by combusting the fuel injected from the injector and reciprocating the piston. The heating the coating material includes injecting the fuel from the injector at least in an early stage of the heating so that the injected fuel adhering to the surface of the coating material is suppressed.