An electrode material for a spark plug includes 22-46 wt % iron (Fe), inclusive, 20-40 wt % nickel (Ni), inclusive, 13-42 wt % cobalt (Co), inclusive, and one or more additional elements selected from aluminum (Al), titanium (Ti), chromium (Cr), boron (B), and niobium (Nb), wherein the electrode material has a coefficient of thermal expansion (CTE) from room temperature to 200° C. that is less than or equal to 11.0×10.sup.−6/° C. In another example, the electrode material includes greater than or equal to 32 wt % iron (Fe), greater than or equal to 36 wt % nickel (Ni), and one or more additional elements selected from aluminum (Al), chromium (Cr), and cobalt (Co). In advantageous embodiments, the electrode material includes greater than or equal to 22 wt % cobalt (Co). Replacing nickel with a higher percentage of cobalt can help reduce the coefficient of thermal expansion (CTE) of the electrode material.

A spark plug including a center electrode; a metallic member forming a tubular shape around an axis of the spark plug, holding the center electrode therein, and having a hole formed in a side wall thereof and extending in a radial direction; and a ground electrode supported in the hole and extending from the hole toward the axis. The ground electrode has a fixing portion formed of metal and fixed to the hole, and an ignition portion containing a noble metal, disposed on a side toward the axis in relation to the fixing portion, and having a discharge surface for forming a gap between the ignition portion and the center electrode. The absolute value of the difference in coefficient of thermal expansion between the metallic member and the fixing portion is smaller than the absolute value of the difference in coefficient of thermal expansion between the metallic member and the ignition portion.

A spark plug includes a tubular metal shell; an insulator including a locking portion locked onto the metal shell; and a cap disposed at a front end side of the metal shell, the cap having a plurality of orifices. The plurality of orifices include orifices with different cross-sectional areas. A sum of the number of one or more largest orifices and the number of one or more large orifices that have a cross-sectional area of larger than or equal to 90% of the one or more largest orifices is smaller than the number of orifices that are other than the one or more largest orifices and the one or more large orifices. A length of the front end portion in an axial direction between a front end of the insulator and a front end of the locking portion is smaller than or equal to 12 mm.

A spark plug includes a tubular metal shell; an insulator including a locking portion locked onto the metal shell; and a cap disposed at a front end side of the metal shell, the cap having a plurality of orifices. The plurality of orifices include orifices with different cross-sectional areas. A sum of the number of one or more largest orifices and the number of one or more large orifices that have a cross-sectional area of larger than or equal to 90% of the one or more largest orifices is smaller than the number of orifices that are other than the one or more largest orifices and the one or more large orifices. A length of the front end portion in an axial direction between a front end of the insulator and a front end of the locking portion is smaller than or equal to 12 mm.

A spark plug includes a tubular metal shell; an insulator including a locking portion locked onto the metal shell; and a cap disposed at a front end side of the metal shell, the cap having a plurality of orifices. The plurality of orifices include orifices with different cross-sectional areas. A sum of the number of one or more largest orifices and the number of one or more large orifices that have a cross-sectional area of larger than or equal to 90% of the one or more largest orifices is smaller than the number of orifices that are other than the one or more largest orifices and the one or more large orifices. A length of the front end portion in an axial direction between a front end of the insulator and a front end of the locking portion is smaller than or equal to 12 mm.

A spark plug includes a tubular metal shell; an insulator including a locking portion locked onto the metal shell; and a cap disposed at a front end side of the metal shell, the cap having a plurality of orifices. The plurality of orifices include orifices with different cross-sectional areas. A sum of the number of one or more largest orifices and the number of one or more large orifices that have a cross-sectional area of larger than or equal to 90% of the one or more largest orifices is smaller than the number of orifices that are other than the one or more largest orifices and the one or more large orifices. A length of the front end portion in an axial direction between a front end of the insulator and a front end of the locking portion is smaller than or equal to 12 mm.

A prechamber spark plug having a thermally enhanced prechamber cap with a thermally conductive core, such as one made from a copper-, aluminum- and/or silver-based material. Due to its location and function, a prechamber cap is exposed to thermal energy from a pre-combustion process taking place within a prechamber, as well as thermal energy from a combustion process taking place in a main combustion chamber. Thus, the prechamber cap is being heated on both its interior and its exterior and, if not sufficiently cooled, can become so hot that it undesirably triggers preignition events in the engine. The thermally enhanced prechamber cap may include a main body with an interior surface and an exterior surface, a thermally conductive core with one or more thermal segments and insert segments, and one or more openings extending between a prechamber and a main combustion chamber, where each opening extends through an insert segment that is designed to resistant to corrosion and/or erosion.

A prechamber spark plug having a thermally enhanced prechamber cap with a thermally conductive core, such as one made from a copper-, aluminum- and/or silver-based material. Due to its location and function, a prechamber cap is exposed to thermal energy from a pre-combustion process taking place within a prechamber, as well as thermal energy from a combustion process taking place in a main combustion chamber. Thus, the prechamber cap is being heated on both its interior and its exterior and, if not sufficiently cooled, can become so hot that it undesirably triggers preignition events in the engine. The thermally enhanced prechamber cap may include a main body with an interior surface and an exterior surface, a thermally conductive core with one or more thermal segments and insert segments, and one or more openings extending between a prechamber and a main combustion chamber, where each opening extends through an insert segment that is designed to resistant to corrosion and/or erosion.

A spark plug 100 of the present disclosure includes a center electrode 20; a metallic member provided to form a tubular shape around an axis AX of the spark plug, holding the center electrode 20 therein in an insulated state, and having a hole 55 formed in a side wall thereof and extending in a radial direction; and a ground electrode 30 supported in the hole 55 and extending from the hole 55 toward the axis AX. The ground electrode 30 has a fixing portion formed of a metal and fixed to the hole 55, and an ignition portion 39 containing a noble metal, disposed on a side toward the axis AX in relation to the fixing portion, and having a discharge surface for forming a gap G between the ignition portion and the center electrode 20. The absolute value of the difference in coefficient of thermal expansion between the metallic member and the fixing portion is smaller than the absolute value of the difference in coefficient of thermal expansion between the metallic member and the ignition portion 39.

The present invention pertains to a spark plug for an internal combustion engine, comprising a metal outer shell extending in a longitudinal direction from a proximal end to a distal tip end configured to be oriented towards a combustion chamber, said outer shell comprising a fixation portion for attachment of the spark plug to a metal sleeve of the internal combustion engine and arranged at a region proximal of the tip end, wherein the outer shell furthermore comprises a first contact surface arranged at a region distal of the fixation portion and configured to contact a distal end of the sleeve, when the spark plug is attached to the sleeve.