An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a first wall, a second wall, a first case segment and a second case segment. The first wall extends axially along and circumferentially about an axial centerline. The second wall extends axially along and circumferentially about the axial centerline. The second wall is radially outboard of and axially overlaps the first wall. The first case segment is configured to form a first portion of the first wall and a first portion of the second wall. The second case segment is configured to form a second portion of the first wall and a second portion of the second wall. The second case segment is circumferentially adjacent and attached to the first case segment at a joint.

Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.

An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a first wall, a second wall, a first case segment and a second case segment. The first wall extends axially along and circumferentially about an axial centerline. The second wall extends axially along and circumferentially about the axial centerline. The second wall is radially outboard of and axially overlaps the first wall. The first case segment is configured to form a first portion of the first wall and a first portion of the second wall. The second case segment is configured to form a second portion of the first wall and a second portion of the second wall. The second case segment is circumferentially adjacent and attached to the first case segment at a joint.

An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a plurality of walls and a plurality of case segments. Each of the walls extends axially along and circumferentially about an axial centerline. The walls include a first wall and a second wall radially outboard of and axially overlapping the first wall. Each of the case segments is configured to form a respective portion of the first wall and a respective portion of the second wall. The case segments include a first case segment and a second case segment circumferentially adjacent and attached to the first case segment at a joint.

A method of forming an engine is provided. A liner is cast with an outer surface with a first texture extending circumferentially from a first end to a second end of the liner. A circumferential section of the outer surface of the liner is coated with an insulative, thermoset material with a lower thermal conductivity than the texture. An engine and a cylinder liner for the engine are provided. The liner has first and second ends with an outer surface extending therebetween. An outer surface of the liner has axial sections defining a texture and an insulative thermoset coating to form material interfaces with the block with different thermal conductivities thereacross.

A method of forming an engine is provided. A liner is cast with an outer surface with a first texture extending circumferentially from a first end to a second end of the liner. A circumferential section of the outer surface of the liner is coated with an insulative, thermoset material with a lower thermal conductivity than the texture. An engine and a cylinder liner for the engine are provided. The liner has first and second ends with an outer surface extending therebetween. An outer surface of the liner has axial sections defining a texture and an insulative thermoset coating to form material interfaces with the block with different thermal conductivities thereacross.

A customizable gating system for metal casting that includes a duct assembly formed from refractory conduit components is disclosed. The gating system is configured to deliver molten metal to a gateway for a mold. The duct assembly is formed from refractory conduit components that can withstand the high temperatures of molten metal and include advantageous features for forming the components, for adjusting the length of conduit components as needed to provide a customized duct assembly, and for interconnecting components to form a duct assembly.

Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.

A tool and a process for forming a vehicle component is provided. An insert has a lost core generally encapsulated by a cast metal shell. The insert has an anchor surface and a first locating member spaced apart therefrom, and is shaped to form a fluid passage in the vehicle component. A first die is configured to mate with the anchor surface and constrain the insert. A second die defines a first locator recess sized to receive the first locating member and constrain the insert. The first and second dies mate with one another to form the tool. The first and second dies constrain the insert in multiple degrees of freedom.

The present invention provides a method for manufacturing a composite double-metal fracture splitting connecting rod, comprising the steps of: providing a moveable spacer at a large end of a mold cavity of a connecting rod, to divide the mold cavity into two separate parts; casting a connecting rod body and a connecting rod cap with material for the main body of the connecting rod; removing the spacer from the mold cavity when the majority of the material is solidified, then injecting material for a fracture splitting region into an empty mold cavity obtained after the removal of the spacer, and metallurgically bonding the two types of material to form a composite double-metal casting; then, separating the connecting rod body from the connecting rod cap by a fracture splitting apparatus along preset fracture surfaces; and positioning and accurately assembling through engaged staggered structures on the two fracture surfaces.