An object of the present invention is to enhance the thermal efficiency of an engine, to provide a film having low thermal conductivity and low heat capacity and being free from separation, drop-off and the like and excellent in durability and reliability. According to the present invention, an engine combustion chamber structure, wherein an anodic oxide film having a thickness of from more than 20 μm to 500 μm and a porosity of 20% or more is formed on the inner surface of the engine combustion chamber, and a manufacturing method thereof are provided.

A porous alumina layer with a sealer (i.e., a coating layer) is formed on a top surface or a piston (i.e., a second cavity surface and a second squish surface) and a surface of a bottom surface of a cylinder which forms a cavity area CA (i.e., a first cavity surface). The porous alumina layer without the sealer (i.e., an exposed layer) is formed on a surface of the bottom surface which forms a squish area SA (i.e., a first squish surface).

A porous alumina layer with a sealer (i.e., a coating layer) is formed on a top surface or a piston (i.e., a second cavity surface and a second squish surface) and a surface of a bottom surface of a cylinder which forms a cavity area CA (i.e., a first cavity surface). The porous alumina layer without the sealer (i.e., an exposed layer) is formed on a surface of the bottom surface which forms a squish area SA (i.e., a first squish surface).

A piston for a diesel engine is prepared as a piston for a direct injection engine, a cavity face of the piston is grinded, and a squish face thereof is masked. Next, a high-purity aluminum coating is formed on the cavity face, and the masking of the squish face is removed and the entire area of the piston top face is subjected to an anodizing treatment. Thereafter, the cavity face is masked, and the squish face is subjected to a sealing treatment.

On a piston top surface, a cavity and two valve recesses are formed. On the piston top surface, a first heat insulating film is formed. However, on edge portions, a second heat insulating film different from the first heat insulating film is formed. The second heat insulating film is formed along the edge portions. The first heat insulating film is composed of porous alumina and a sealer. The second heat insulating film is composed of only porous alumina.

A piston for a diesel engine is prepared as a piston for a direct injection engine, a cavity face of the piston is grinded, and a squish face thereof is masked. Next, a high-purity aluminum coating is formed on the cavity face, and the masking of the squish face is removed and the entire area of the piston top face is subjected to an anodizing treatment. Thereafter, the cavity face is masked, and the squish face is subjected to a sealing treatment.

On a piston top surface, a cavity and two valve recesses are formed. On the piston top surface, a first heat insulating film is formed. However, on edge portions, a second heat insulating film different from the first heat insulating film is formed. The second heat insulating film is formed along the edge portions. The first heat insulating film is composed of porous alumina and a sealer. The second heat insulating film is composed of only porous alumina.

A device and method for preventing and removing carbon deposit build-up on a piston/cylinder assembly of an engine, including a diesel engine, is disclosed. The device includes a cylinder having an inner sleeve for receiving a piston, a carbon scraping ring positioned on the cylinder sleeve, the carbon scraping ring including an inner surface, and an abradable coating applied to the inner surface of the carbon scraping ring providing a wearable surface between the piston and the cylinder sleeve. The abradable coating has a wearable surface, which conforms to the shape created by the movement of the piston and the cylinder sleeve and carbon scraping ring, creating a substantially zero clearance fit between the piston and the carbon scraping ring. The clearance may reduce oil consumption and improve sealing of the cylinder and piston, thereby reducing blow-by.