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.

Methods are provided for manufacturing a component. In one method, first metal material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material, A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

A coating for a carrier material made of a steel material for joining to an aluminum material includes a first sublayer on the core part side and a second sublayer on the outside. On average, the coating includes approximately 1 to 10 wt. % silicon and iron, the remainder being aluminum. The first sublayer at least approximately includes 42 wt. % iron, 11 wt. % silicon, and no more than approximately 45 wt. % aluminum, which constitutes the remainder, and has a thickness of no more than approximately 3.5 m. The second sublayer includes approximately 1 to 10 wt. % silicon, the remainder being aluminum, and has a thickness of approximately 5 to approximately 95 mm.

A rotor designed as a reluctance rotor includes a laminated core which defines an axis and has end faces. The laminated core includes sheets which are at least partly axially layered, with the sheets having flux-conducting portions and flux-blocking portions to form a specified number of poles. A cage made of electric conductors runs in a substantially axial direction and is connected at the end faces of the laminated core by short-circuit rings. The conductors are located in a radially outer region of at least some of the flux-blocking portions arranged one behind another substantially in the axial direction, with the conductors defining conductor bars formed by conductive material at a quantity determinative to define an internal diameter of the conductor bars.

A dissimilar metal joint structure includes a first and second joining materials and a three-dimensional structural body. The structural body is joined to the top of the first joining material. Spaces in the structural body are filled with the second joining material, so that the second joining material is geometrically integrated with the structural body. The structural body is joined to the first joining material at an interface. The second joining material is charged into the spaces in the structural body and is integrated with the structural body. The first and second joining materials are joined together via the structural body. Because the second joining material is charged into the spaces in the structural body, the second joining material and the structural body are strongly joined and integrated together by the anchor effect. Inducing metallurgical reaction at the interface between the first and second joining materials can increase bonding strength.

The method for the production of an element subject to wear, comprising a metal matrix and at least a core of hard material. The method provides a first step in which a temporary aggregation structure is prepared with at least partly open pores, which volatilize or in any case eliminate at least partly when subjected to heating. A second step in which, on the whole internal and external surface of said temporary aggregation structure, a liquid mixture of a binder with metal powders which contain hard elements or their precursors is uniformly distributed. A third step in which the temporary aggregation structure is deteriorated by means of a thermal action of controlled heating, so as to take at least part of the temporary aggregation structure to evaporation, rendering free a volume inside the core, and to consolidate the mixture according to the conformation of the temporary aggregation structure. A fourth step in which the core is disposed in a mold so as to only partly occupy the free volume of the mold. A fifth step in which a molten metal material is cast in the mold, which metal occupies the free volume and the volume that has been made free, both inside and outside the core, so as to anchor to the latter and thus form a single body.

A mold assembly for use in forming a component having an outer wall of a predetermined thickness includes a mold and a jacketed core. The jacketed core includes a jacket that includes a first jacket outer wall coupled against an interior wall of the mold, a second jacket outer wall positioned interiorly from the first jacket outer wall, and at least one jacketed cavity defined therebetween. The at least one jacketed cavity is configured to receive a molten component material therein. The jacketed core also includes a core positioned interiorly from the second jacket outer wall. The core includes a perimeter coupled against the second jacket outer wall. The jacket separates the perimeter from the interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.

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 of forming an assembly is provided. The method includes forming an insert, coating the insert with a bond material and placing the insert within a casting mold or die. The casting mold or die is purged with an inert gas and the casting mold or die is filled with molten metal to encapsulate the insert. The encapsulated insert is diffusion bonded to the molten metal to form a diffusion bonded insert, which is placed within a cavity of a secondary casting mold or die. The secondary casting mold or die is filled with molten metal to form a composite casting assembly. After or during the casting, the composite casting assembly is heat treated. In another method of the present disclosure, the insert includes ferrous alloys, nickel-based alloys, super alloys, and nonferrous alloys.

A mold assembly for use in forming a component having an outer wall of a predetermined thickness is provided. The mold assembly includes a mold that includes an interior wall that defines a mold cavity within the mold. The mold assembly also includes a jacketed core positioned with respect to the mold. The jacketed core includes a jacket that includes an outer wall. The jacketed core also includes a core positioned interiorly of the jacket outer wall. The jacket separates a perimeter of the core from the mold interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.