A method is provided for designing and producing fiber-reinforced polymer (FRP) pistons. Pistons made with FRP have a lower mass than prior art metal pistons conferring advantageous engine efficiency and stability. FRP pistons also increase the thermal efficiency of engines by having a lower thermal conductivity, with tighter piston-to-bore clearance, and/increased air-fuel ratio than pistons of metal. The technical parameters of the piston are identified, and a piston body blank is produced. The blank is then machined, a bearing surface for the pin bore is created, the piston blank is optionally coated, is optionally subjected to Heavy Metal Ion Implantation (HMII) treatment and is subjected to sodium silicate impregnation to produce the final pistons.

A piston, particularly a piston for use in a diesel engine, particularly a heavy duty diesel engine, is formed from a billet of metal, such that the finished piston has a mass that is at least 50%, and, more preferably, up to about 62%, of the mass of the billet. Other than finishing steps, the piston is formed with a closed gallery, without loss of mass through machining processes.

A piston, particularly a piston for use in a diesel engine, particularly a heavy duty diesel engine, is formed from a billet of metal, such that the finished piston has a mass that is at least 50%, and, more preferably, up to about 62%, of the mass of the billet. Other than finishing steps, the piston is formed with a closed gallery, without loss of mass through machining processes.

A compact pulley puller includes a hollow cylindrical barrel with a gland at each end, a hub clamp formed on each gland, a rod and a piston. Each hub clamp grips a particular size hub of a pulley to be removed or installed. The rod of the puller extends against the shaft of a pulley to remove the pulley. To install a pulley, the rod is threadedly secured to the shaft of the pulley, and the rod of the puller is retracted.

A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.

A pin including recesses extending longitudinally between opposite ends, and a piston assembly including the pin, for a two-stroke engine, is provided. The recesses preferably have a radius of curvature less than a radius of curvature of the remaining outer surface of the pin. The pin is rotationally fixed relative to the connecting rod. As the connecting rod swings back and forth during operation, some of the recesses rotate beyond the load bearing region of the pin joint where oil is located, allowing oil to fill the recesses. As the pin swings back, these recesses carrying the oil enter the load bearing region of the pin joint, transferring the oil with them. Preferably, at least one of the recesses aligns with an oil opening in the pin, which aligns with an oil hole in the connecting rod, to receive and distribute oil along the full length of the pin.

A pin including recesses extending longitudinally between opposite ends, and a piston assembly including the pin, for a two-stroke engine, is provided. The recesses preferably have a radius of curvature less than a radius of curvature of the remaining outer surface of the pin. The pin is rotationally fixed relative to the connecting rod. As the connecting rod swings back and forth during operation, some of the recesses rotate beyond the load bearing region of the pin joint where oil is located, allowing oil to fill the recesses. As the pin swings back, these recesses carrying the oil enter the load bearing region of the pin joint, transferring the oil with them. Preferably, at least one of the recesses aligns with an oil opening in the pin, which aligns with an oil hole in the connecting rod, to receive and distribute oil along the full length of the pin.

A piston for an internal combustion engine includes a lower portion and an upper portion. An upper joining plane is positioned between the upper and lower extending through the outer circumference of the piston. At least one lower joining plane is positioned between the upper and lower portions. A solder gap is defined in the upper and lower joining planes wherein a solder containing iron is inserted to fixedly join the upper and lower portions together. Methods for producing pistons through connection of the lower portion to the upper portion with solder are also disclosed.

A method for producing a piston for an internal combustion engine may include the steps of: producing a first blank corresponding to a piston main body via a deformation process; producing a second blank corresponding to a piston ring part via at least one of a deformation process and a casting process; pre-machining the first blank and the second blank, and finishing a welding surface of the first blank and a welding surface of the second blank via machining; connecting the first blank and the second blank via welding the welding surface of the first blank to the welding surface of the second blank to form a piston body; and performing at least one of a secondary machining process and a finish machining process on the piston body to produce the piston.