A method for producing a cast aluminum component having at least one reinforcing element arranged therein includes producing a core by placing at least one reinforcing element in a first mold and at least partially overmolding the at least one reinforcing element with a foam material. In the alternative, or in addition to, a core is produced by surrounding an inner element composed of a foam material by at least one reinforcing element. The method includes placing the core in a second mold and pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

A marine engine has a cylinder block defining at least one cylinder bore and a cylinder liner providing a running surface for a piston in the cylinder bore. The cylinder liner is non-axisymmetric relative to a center axis of the cylinder liner. The cylinder block defines a pocket that retains the cylinder liner and prevents the cylinder liner from rotating about the center axis. Novel cylinder liners, assemblies and methods are provided for forming a marine engine having the cylinder block with the cylinder liner formed therein.

A diecasting tool has an insert for producing a cooled motor housing. The diecasting tool has mould halves including: a stationary mould half; and movable mould half. One of the mould halves has a cylindrically extending annular gap having a central axis. The moveable mould half is arranged so as to be movable parallel to the central axis. The insert is arranged in the cylindrically extending annular gap. The insert is a bush. One end of the bush projects into a mould cavity, which is formed by the stationary mould half and the movable mould half, and is at least partially surrounded in a form-fitting manner by the casting material in a state when the casting material is cast.

A method of forming a thermally isolated exhaust port, the method comprising placing a chill device around an exhaust port core in a mold for an engine cylinder head, forming the engine cylinder head with an exhaust port using a casting process, generating, in the cylinder head with the exhaust port during the casting process, nodular graphite iron proximate the chill device around the exhaust port core, and forming the thermally isolated exhaust port containing nodular graphite iron in the cylinder head.

A method of forming a thermally isolated exhaust port, the method comprising applying an endothermic material to an exhaust port core in a mold for an engine cylinder head, forming the engine cylinder head with an exhaust port using a casting process, generating, in the cylinder head with the exhaust port during the casting process, nodular graphite iron proximate the endothermic material around the exhaust port core, and forming the thermally isolated exhaust port containing nodular graphite iron in the cylinder head.

Disclosed are a cylinder liner for insert casting and a method for manufacturing the same. In particular, the cylinder liner for insert casting has cooling and warming performances suitable for functions of respective parts by imparting multiple layers having different thermal conductivity on the surface of the cylinder liner for insert casting, such that the cylinder liner can be used for vehicle cylinder blocks.

A cylinder liner assembly for inclusion in the cylinder bore of an internal combustion engine includes a sleeve-like cylinder liner and an anti-polishing ring to scrape combustion deposits from a piston reciprocally movable along an axis line of the cylinder liner. A fire dam may axially protrude from a first liner end of the cylinder liner and may have an obliquely angled chamfer disposed therein circumscribing the axis line. To locate the anti-polishing ring proximate to the top land of the piston when at the top dead center position, the anti-polishing ring can include a cuff header disposed at the first cuff end that is generally triangular and has an angled undercut corresponding to the obliquely angled chamfer. When mated, the chamfer and angled undercut abut against each other.

Provided is a spiny liner that may further improve bonding strength when being integrated with metal on the outer peripheral surface side. The spiny liner includes a plurality of projections including constricted projections on the surface. Denoting the number of constricted projections per 100 mm2 out of the projection by Pc, the average height of projections by h (mm), and the average of maximum thicknesses and the average of minimum thicknesses of any 20 projections out of the constricted projections by dw (mm) and dn (mm), respectively, the total value of (I) and (II) below is 1.55 or more.

(I)=Pc×[(0.35 hπ/12)×(2dw.sup.2−dw×dn−dn.sup.2)]

(I)=Pc×{(dn.sup.2/4)×r×0.35h}

A defective engine block recycling method in a continuous casting line includes inserting a bore pin into an engine block mold, fitting a real liner to an outer circumferential surface of the bore pin, and injecting molten aluminum into the engine block mold to cast an engine block body. If an abnormality is generated in the engine block mold or the molten aluminum and if a defect is expected to generate in the engine block body, a defective engine block unit is produced by fitting a dummy liner, which is made of a material identical with or similar to a material of the engine block body, to the bore pin. The defective engine block unit thus produced is directly melted and recycled.

A cylinder liner for an internal combustion engine may include an outer circumferential surface defined by the cylinder liner composed of a gray cast iron for integrally casting onto a cast material of an engine block. A bonding component may be included for strengthening a bond of the outer circumferential surface to the cast material of the engine block. The bonding component may include at least one of a wire mesh and a wire grid that does not melt during a casting operation of the engine block. The bonding component may be arranged at least in a predefined region on the outer circumferential surface. The bonding component may be welded at least partially to the outer circumferential surface.