A piston for an internal combustion engine including a cooling gallery and a complex combustion surface is provided. The piston includes an upper crown member joined to a lower member, for example by hybrid induction welding. A complex combustion bowl is formed in the upper crown member by forging. The combustion bowl includes at least one protrusion, and typically a plurality of protrusions spaced from one another. After the forging step and before the joining step, portions of an undercrown surface located opposite the spaces between the protrusions are machined, and portions located directly opposite the protrusions are left as-forged. The crown member is joined to the lower member, for example by hybrid induction welding.

Disclosed herein are an aluminum alloy for an insert ring, an aluminum insert ring using the same, and a piston manufacturing method using the same, and, particularly, are an insert ring manufactured to have high strength and abrasion resistance and reduce its weight by adjusting aluminum alloy components, and a method of manufacturing a piston having high bonding properties to the insert ring through the same.

Disclosed herein are an aluminum alloy for an insert ring, an aluminum insert ring using the same, and a piston manufacturing method using the same, and, particularly, are an insert ring manufactured to have high strength and abrasion resistance and reduce its weight by adjusting aluminum alloy components, and a method of manufacturing a piston having high bonding properties to the insert ring through the same.

The invention relates to a cold-formed steel brake piston 1 for a motor vehicle partial-pad disc brake brake pad with a thin-walled structure as a cup open at one end and comprising a base 2 and a wall 3 with a radially outwardly impressed groove 6 in the wall 3 and with a radially inwardly impressed wall projection 7.

The invention has the object of providing a further improved stable steel brake piston construction with an improved interface which can be used flexibly and cost-effectively for both large-bore and small-bore steel brake pistons 1.

This object is accomplished by making the wall 3 with at least one groove 14 and at least one land 15 at a distance from wall projection 7 profiled in such a way that wall 3 has wall surface areas of varying thickness which are spaced apart from each other in the circumferential direction with a spacing V.

A piston includes an upper member having a crown and a combustion surface extending radially inward from the crown. The upper member includes concentrically oriented first and second upper connecting surfaces integrally formed on the bottom side of the upper member. At least one of the upper connecting surfaces includes a curvilinear and/or multi-arcuate cross-sectional profile. The piston also includes a lower member having a pair of opposing skirts, each skirt defining a bore. The lower member also includes concentrically oriented first and second lower connecting surfaces integrally formed on a top side of the lower member. The lower member is integrally connected to the upper member by friction welding. The curvilinear and/or multi-arcuate profile enables a shortened distance between the top surface of the crown and the bore centerline of the bore. Methods of manufacturing the piston are also disclosed.

A piston includes an upper member having a crown and a combustion surface extending radially inward from the crown. The upper member includes concentrically oriented first and second upper connecting surfaces integrally formed on the bottom side of the upper member. At least one of the upper connecting surfaces includes a curvilinear and/or multi-arcuate cross-sectional profile. The piston also includes a lower member having a pair of opposing skirts, each skirt defining a bore. The lower member also includes concentrically oriented first and second lower connecting surfaces integrally formed on a top side of the lower member. The lower member is integrally connected to the upper member by friction welding. The curvilinear and/or multi-arcuate profile enables a shortened distance between the top surface of the crown and the bore centerline of the bore. Methods of manufacturing the piston are also disclosed.

A piston for an internal combustion engine is provided. The piston includes a lower part joined to an upper part, for example by friction welding with inertia. The upper part presents a combustion surface and an undercrown surface. The piston also includes a cooling gallery surface provided by the upper part and the lower part. The cooling gallery surface surrounds a volume of space for containing a cooling media. The piston can include serrations in the cooling gallery surface and/or undercrown surface to increase surface area and thus reduce the temperature of the piston. The piston can also include shaped weld curls, instead of or in addition to the serrations, which also increase surface area and reduce the temperature of the piston.

The invention relates to a brake piston 1 for a brake caliper 9 of a disk brake, which is produced using working processes from a metallic material, in particular from a flat metal sheet, and is formed in one piece as a unilaterally open pot with a piston longitudinal axis A, with a piston wall 2 and with a piston head 3.

There is a need for robust and light as well as alternatively constructed, efficiently producible and well guided brake pistons.

The object is achieved firstly in principle on the basis of a cup-shapedly worked brake piston blank 19, in that at least one locally defined, i.e. partially cold-upset or partially ironed, cylindrical piston wall portion is present with a partially deformed piston wall 2 which is configured in adaptively modified manner by plastic material deformation by means of material redistribution (flow) including strain-hardening of its piston wall thickness of s1x.

A piston for an internal combustion engine is provided. The piston includes a lower part joined to an upper part, for example by friction welding with inertia. The upper part presents a combustion surface and an undercrown surface. The piston also includes a cooling gallery surface provided by the upper part and the lower part. The cooling gallery surface surrounds a volume of space for containing a cooling media. The piston can include serrations in the cooling gallery surface and/or undercrown surface to increase surface area and thus reduce the temperature of the piston. The piston can also include shaped weld curls, instead of or in addition to the serrations, which also increase surface area and reduce the temperature of the piston.

An improved piston forging for use in an internal combustion engine is disclosed. The piston forging comprises a crown, a pair of pin towers extending generally axially away from the crown, and a skirt extending generally axially away from the crown. The improved piston forging further comprises a plurality of grains flowing across the piston forging. The plurality of grains are reoriented during the forging operation into a configuration that follows the surfaces and features of the piston forging. More specifically, the plurality of grains are reoriented in a manner that is most beneficial to resist combustion and inertial forces that are enacted upon a machined piston during operation.