A casting device and casting method are provided for producing components, in particular cylinder heads. The device includes a reusable steel upper core, which can be lifted off from the component to be produced and which has a movable displacing element. The displacement element can be pressed into the component to be produced for dense feeding. In a method for producing a cylinder head by casting, wherein the steel upper core is used as a substitution for a sand cover core, for dense feeding the displacing element is pressed into the melt that forms the cylinder head in the solidified state.

A piston for an internal combustion engine and method of construction is provided. The piston has a robust, lightweight monolithic piston body including an upper wall forming a combustion bowl depending radially inwardly from an annular, uppermost combustion surface. An undercrown surface is formed on an underside of the combustion bowl, with at least a portion of the undercrown surface being bounded by diametrically opposite skirt portions, pin bosses and strut portions connecting the skirt portions to the pin bosses. The bounded undercrown surface has an openly exposed surface area, as viewed looking along a central longitudinal axis along which the piston reciprocates, providing an expansive area against which oil being splashed or sprayed can come into direct contact with to enhance cooling the piston while in use. Through channels extending over upper regions of the pin bosses can be provided to further reduce weight and facilitate cooling.

A piston for an internal combustion engine and method of construction is provided. The piston has a robust, lightweight monolithic piston body including an upper wall forming a combustion bowl depending radially inwardly from an annular, uppermost combustion surface. An undercrown surface is formed on an underside of the combustion bowl, with at least a portion of the undercrown surface being bounded by diametrically opposite skirt portions, pin bosses and strut portions connecting the skirt portions to the pin bosses. The bounded undercrown surface has an openly exposed surface area, as viewed looking along a central longitudinal axis along which the piston reciprocates, providing an expansive area against which oil being splashed or sprayed can come into direct contact with to enhance cooling the piston while in use. Through channels extending over upper regions of the pin bosses can be provided to further reduce weight and facilitate cooling.

An insulated composite piston head that includes three or more layers is formed and used in a combustion engine. The first layer is an aluminum or aluminum alloy foam core. The second layer is a metal layer that at least partially encapsulates the foam core; wherein the metal layer is selected to be aluminum or an aluminum alloy. The third layer is a layer of an insulating material located on at least one surface of the metal layer. The deposition of the insulating layer is accomplished via the use of a coaxial laser process.

Piston has crown portion 2 having crown surface 2a defining combustion chamber, thrust-side and anti-thrust-side skirt portions 3a, 3b formed integrally with crown portion and sliding on cylinder wall surface, a pair of apron portions 4a, 4a joined to skirt portions in circumferential direction, recessed portion 6 formed on back surface that is opposite side to crown surface and extending between skirt portions along substantially longitudinal direction, and a plurality of protrusions 7 formed integrally with bottom surface of recessed portion and extending along arrangement direction of skirt portions. At least one end edge in longitudinal direction of protrusion is integrally connected to inner side surface, facing one end edge of protrusion, of recessed portion. Adequate transcription performance to molding surface can therefore be ensured while removing remains of air on bottom side of recessed portion of mold for molding protrusions on crown portion back surface during casting.

Piston has crown portion 2 having crown surface 2a defining combustion chamber, thrust-side and anti-thrust-side skirt portions 3a, 3b formed integrally with crown portion and sliding on cylinder wall surface, a pair of apron portions 4a, 4a joined to skirt portions in circumferential direction, recessed portion 6 formed on back surface that is opposite side to crown surface and extending between skirt portions along substantially longitudinal direction, and a plurality of protrusions 7 formed integrally with bottom surface of recessed portion and extending along arrangement direction of skirt portions. At least one end edge in longitudinal direction of protrusion is integrally connected to inner side surface, facing one end edge of protrusion, of recessed portion. Adequate transcription performance to molding surface can therefore be ensured while removing remains of air on bottom side of recessed portion of mold for molding protrusions on crown portion back surface during casting.

Methods, assemblies and apparatuses are for forming a cooling jacket in a cast part of a marine engine, for example in a cylinder head for the marine engine. A cooling jacket core comprises a longitudinally elongated first portion that forms a first flow path for conveying cooling fluid through the cast part in a first direction and a longitudinally elongated second portion that forms an opposite, second flow path for conveying cooling fluid through the cast part in an opposite, second direction. At least one bridge integrally supports the first and second portions with respect to each other during casting. At least one plug is configured to fit in the cast part where the bridge was located so as to separate the first and second flow paths from each other while sealing the first and second flow paths from an opposite side of the cast part.

Methods, assemblies and apparatuses are for forming a cooling jacket in a cast part of a marine engine, for example in a cylinder head for the marine engine. A cooling jacket core comprises a longitudinally elongated first portion that forms a first flow path for conveying cooling fluid through the cast part in a first direction and a longitudinally elongated second portion that forms an opposite, second flow path for conveying cooling fluid through the cast part in an opposite, second direction. At least one bridge integrally supports the first and second portions with respect to each other during casting. At least one plug is configured to fit in the cast part where the bridge was located so as to separate the first and second flow paths from each other while sealing the first and second flow paths from an opposite side of the cast part.

A cylinder liner for insertion into an aluminum internal-combustion engine block may include a cylindrical body of cast iron having a circumferential external surface. The cylinder liner may also have a coating deposited on and surrounding the external surface. The external surface may have a specific roughness, and the coating may include at least 98% by volume of pure nickel, and a remainder composed of impurities.

A cylinder liner for insertion into an aluminum internal-combustion engine block may include a cylindrical body of cast iron having a circumferential external surface. The cylinder liner may also have a coating deposited on and surrounding the external surface. The external surface may have a specific roughness, and the coating may include at least 98% by volume of pure nickel, and a remainder composed of impurities.