Methods for manufacturing components that include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles and the component is a metal matrix composite having an aluminum matrix that contains dispersions of TiB.sub.2 particles and Al.sub.3Ti particles. Optionally, the metal matrix composite may include particles of an intermetallic compound of aluminum and at least one alloying element.

The present invention relates to a method for producing a piston (1) for an internal combustion engine from a piston upper part (2) and a piston lower part (3).

The method has the following method steps: producing a piston upper part (2) having a piston top (6), at least parts of a ring section (12) and at least part (7) of a cooling channel (8), by forging or casting for example, producing the piston lower part (3) and closing the part (7) of the cooling channel (8) which is arranged in the piston upper part (2) by means of an additive method, finish-machining the piston (1), including the production of at least one annular groove (4) in the ring support (5) for receiving a piston ring.

In this way, it is possible to provide a piston (1) that has a greater strength in its piston upper part (2), which is subjected to high thermal and mechanical loads, than in its piston lower part (3), which is subjected to lower thermal and mechanical loads, and that permits greater freedom of manufacture in respect of the shape of the piston lower part (3).

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

A light-weight, high-strength compressor component having at least one fluid delivery feature that is formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure has at least one fluid delivery feature for permitting fluid flow through the body portion of the light-weight, high-strength compressor component. The fluid delivery feature may be a flow channel, a fluid delivery port, a porous fluid delivery feature, or the like that serves to transfer fluids through the component, such as refrigerant and/or lubricant oils. Methods of making such compressor components via additive manufacturing processes are also provided.

A method for producing a cermet composition, including mixing a first predetermined amount of a yttria stabilized zirconia powder with between 2 and 8 weight percent mu-metal powder to define a homogeneous admixture, oxidizing the mu-metal in the admixture, forming the homogeneous admixture into a green body, calcining the green body in a first reducing atmosphere to remove oxygen from the oxidized mu-metal to yield a calcined body, and sintering the calcined body in a second reducing atmosphere to yield a densified body having no more than 0.8% porosity. The densified body has a plurality of mu-metal particles distributed therethrough, a hardness of at least 1450 HV, flexural strength of at least 200 kPSI, and a relative permeability μ/μ.sub.o of at least 850.

When forming valve seat coats at opening portions (16a.sub.1 to 16a.sub.8) of intake ports (16) provided at a cylinder block mounting surface (12a) of a semimanufactured cylinder head (3), the nozzle of a cold spray apparatus moves along a nozzle movement path for air intake (Inp1) that is set between any two of the plurality of opening portions (16a.sub.1 to 16a.sub.8), while continuing to spray a raw material powder. When forming valve seat coats at opening portions (17a.sub.1 to 17a.sub.8) of exhaust ports (17), the nozzle moves along a nozzle movement path for air exhaust (Enp1) that is set between any two of the plurality of opening portions (17a.sub.1 to 17a.sub.8), while continuing to spray the raw material powder.

A method for the production of a cylinder head for an internal combustion engine. The production method presentes the steps of: dividing the cylinder head into a main part, where there is the flame deck making up the crown of each cylinder, and an operating part, where there are the housings of the control means of the valves; manufacturing, at first, the sole main part of the cylinder head by means of a casting process in a mould; and manufacturing, subsequently, the operating part of the cylinder head by means of additive manufacturing, which adds layer upon layer starting from the previously manufactured main part of the cylinder head.

A monolithic fuel delivery system for gasoline direct injection to an engine. The system has a common rail tube body from which injector sockets smoothly and seamlessly extend. Uninterrupted junctions are formed between the rail tube body and the injector sockets. The seamless junctions present a sealed relationship between the tube body and the injector sockets.

A method for manufacturing a metallic component including the steps of providing a capsule, which defines at least a portion of the shape of the metallic component, arranging metallic material in the capsule, sealing the capsule, subjecting the capsule to Hot Isostatic Pressing for a predetermined time, at a predetermined pressure and at a predetermined temperature, and optionally, removing the capsule. The metallic material is at least one pre-manufactured coherent body, which pre-manufactured coherent body being made of metallic powder, wherein at least a portion of the metallic powder is consolidated such that the metallic powder is held together into a pre-manufactured coherent body. At least one portion of the pre-manufactured coherent body is manufactured by Additive Manufacturing by subsequently arranging superimposed layers of metallic powder.

An aluminum alloy is disclosed that is suitable for casting and additive manufacturing processes. The aluminum alloy may be used in the casting and additive manufacturing of engine blocks and/or cylinder heads of modern internal combustion engines. The aluminum alloy exhibits improved ductility and fatigue properties suitable for elevated operating temperatures from about 250° C. to 350° C. The alloy includes about, by weight, 4-10% Copper (Cu), 0.1-1.0% Manganese (Mn), 0.2 to 5% Magnesium (Mg), 0.01-1.0% Cerium (Ce), 0.01-2% Nickel (Ni), 0.01-0.8% Chromium (Cr), 0.01-1.0% Zirconium (Zr); 0.01-1.0% Vanadium (V), 0.01-0.3% Cobalt (Co), 0.01-1.0% Titanium (Ti), 1-200 ppm Boron (B), 1-200 ppm Strontium (Sr), 0.5% max Iron (Fe), 0.1% max other trace elements, and balance of aluminum (Al).