A cast iron having high strength, hardness, and thermal conductivity for a cylinder liner of an internal combustion engine is provided. The cast iron includes 3.2 wt. % to 3.8 wt. % carbon, 2.2 wt. % to 3.2 wt. % silicon, 0.5 wt. % to 1.3 wt. % copper, and at least 75.0 wt. % iron, based on the total weight of the cast iron. The cast iron further includes 0.01 wt. % to 0.5 wt. % manganese, 0.01 wt. % to 0.2 wt. % chromium, up to 0.3 wt. % phosphorous, up to 0.05 wt. % sulfur, up to 0.2 wt. % tin, and up to 0.1 wt. % magnesium, based on the total weight of the cast iron. Preferably, the cast iron is free of molybdenum, nickel, and vanadium. The cast iron is also heat treated and solidifies to achieve fully spheroidal graphite.

A method for manufacturing a tool having one or more internal channels includes forming one or more channel cores by additive manufacturing, coating a metal onto the one or more channel cores to form a metal tube on each of the one or more channel cores, positioning the one or more metal tubes into a casting mold having a shape of a tool, and casting a molten metal into the casting mold to form the tool having the one or more internal channels corresponding to the one or more channel cores.

Provided are casting products for cooling heating elements, the casting products including: a body made of a metal material; and a cooling pipe providing a path through which a cooling fluid flows, and being made of an aluminum alloy material, wherein the body includes a plate-shaped plate portion, protrusion extensions protruding from the plate portion and extending along the cooling pipe so that at least part of the cooling pipe is fully buried, and a cooling pin structure formed integrally with the plate portion, and the cooling pipe is formed in such a way that a first pipe thickness of the cooling pipe having a cross-sectional shape in a first direction is greater than a second pipe thickness in a second direction perpendicular to the first direction, and the first direction is in parallel to the plate portion, and the second direction is a thickness direction of the plate portion.

A cylinder block assembly for a V-engine is provided. In one example, the cylinder block assembly includes a cylinder block including a plurality of cylinders divided into a first cylinder bank and a second cylinder bank, a valley positioned between the first and second cylinder banks, and a plurality of crankshaft supports. The cylinder block assembly further includes a structural frame including an interior surface coupled to the plurality of crankshaft supports and two top surfaces arranged above the interior surface and on opposing sides of the assembly, where each top surface is coupled to the cylinder block above a top of the plurality of crankshaft supports.

A cylinder liner for an internal combustion engine may include an aluminum alloy material including a magnesium content of at least 0.3% by weight, a liner body having a circumferential face, and an adapter layer of silicon oxide disposed on the circumferential face. The adapter layer may include at least one of a potassium oxide content and a sodium oxide content of greater than or equal to 0% by weight.

A method for producing a cast component may include providing an insert part including an insert body having a circumferential face; coating the circumferential face with an adapter layer made of silicon oxide; arranging the insert part in a casting mold; and positively locking a casting encapsulation of the insert part and the adapter layer with an aluminum alloy to produce the cast component, wherein the aluminum alloy has a magnesium proportion of at least 0.3% by weight.

A cylinder block is provided. The cylinder block includes a cylinder, two crankshaft supports at a bottom of the cylinder block, a cylinder head engaging surface at a top of the cylinder block, and first and second exterior sidewalls, the first exterior sidewall extending from the cylinder head engaging surface to a first structural frame engaging surface positioned above a centerline of the two crankshaft supports.

A method for forming a product having cast-in components provides an insulating barrier of solidified sand formed next to the insider diameter of the cast-in component. The center of the solidified sand is hollow. Before pouring the molten metal into the primary runner/riser system that feeds the portion of the mold that will create the actual part, the molten material is poured into the hollow portion of the solidified sand through a separate runner/riser system. This molten metal provides the energy necessary to heat the cast-in part to an acceptable temperature. The temperature can be controlled by the shape, thickness and material of the insulating member. This controlled time/temperature profile enables the creation of a final cast product that demonstrates good quality properties at the cast/insert interface. The method of the disclosed inventive concept has the added benefit of not altering the resulting part itself.

A structural frame is provided. The structural frame includes a bottom surface, first and second cylinder block sidewall engaging surfaces, the first and second cylinder block sidewall engaging surfaces positioned above the bottom surface at a height that is above a centerline of a crankshaft support included in a cylinder block when the structural frame is coupled to the cylinder block.

An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.