A cylinder head assembly for an internal combustion engine includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head and having an integrally cast wastegate housing. The turbocharger housing is configured to receive a turbocharger cartridge rotatably supporting a shaft coupled between a compressor wheel and a turbine wheel. The integrally cast wastegate housing defines a wastegate chamber configured to receive a wastegate valve, a flow of exhaust gas from the turbine wheel, and a flow of wastegate exhaust gas.

A cylinder head assembly for an internal combustion engine includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head and having an integrally cast wastegate housing. The turbocharger housing is configured to receive a turbocharger cartridge rotatably supporting a shaft coupled between a compressor wheel and a turbine wheel. The integrally cast wastegate housing defines a wastegate chamber configured to receive a wastegate valve, a flow of exhaust gas from the turbine wheel, and a flow of wastegate exhaust gas.

An apparatus and methods are provided for removing trapped air from a cooling system of an internal combustion engine. The apparatus includes an air bleed valve configured to allow the trapped air to be vented from a water jacket comprising an engine cylinder head. The air bleed valve is coupled with a hollow portion disposed at a top of the cylinder head. A topmost chamber within the hollow portion is in fluid communication with the water jacket. The water jacket includes angled upper walls near the hollow portion configured to direct the trapped air into the topmost chamber. An air bleed line is coupled with the air bleed valve and configured to direct the trapped air out of the topmost chamber to a suitable coolant reservoir.

A cylinder head assembly includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head. The integrated cylinder head and turbocharger housing includes: (i) a compact low wetted area to provide an uninterrupted flow path pointed directly at a catalyst face to facilitate achieving cold start emissions targets, (ii) a casting core assembly with specific core geometry and steps for assembly to enable core assembly while meeting all cylinder head and integrated turbine housing functional requirements, (iii) an oxygen sensor disposed pre-turbine in an integrated exhaust manifold, and (iv) a fully integrated PCV make-up air system.

A cylinder head assembly includes a cast cylinder head and a turbocharger housing integrally cast with the cylinder head. The integrated cylinder head and turbocharger housing includes: (i) a compact low wetted area to provide an uninterrupted flow path pointed directly at a catalyst face to facilitate achieving cold start emissions targets, (ii) a casting core assembly with specific core geometry and steps for assembly to enable core assembly while meeting all cylinder head and integrated turbine housing functional requirements, (iii) an oxygen sensor disposed pre-turbine in an integrated exhaust manifold, and (iv) a fully integrated PCV make-up air system.

An internal combustion engine for neutron diffraction analysis is provided. The engine includes an elongated piston chamber formed from an aluminum alloy to ensure maximum neutron visibility into the combustion chamber. An elongated piston assembly reciprocates within the elongated piston chamber, the piston assembly including an upper piston joined to a lower piston. The upper piston and the lower piston are hollow, thereby reducing the reciprocating mass and increasing neutron access to the combustion chamber. The upper piston is lubricated with a neutron-transparent fluorocarbon lubricant such as perfluoropolyether (PFPE), while the lower piston and the crankcase are lubricated with hydrocarbon lubricant. The engine enables 3D and time-resolved measurements of strain, stress, and temperature, as well as phase transformation, texture, and microstructure.

An internal combustion engine for neutron diffraction analysis is provided. The engine includes an elongated piston chamber formed from an aluminum alloy to ensure maximum neutron visibility into the combustion chamber. An elongated piston assembly reciprocates within the elongated piston chamber, the piston assembly including an upper piston joined to a lower piston. The upper piston and the lower piston are hollow, thereby reducing the reciprocating mass and increasing neutron access to the combustion chamber. The upper piston is lubricated with a neutron-transparent fluorocarbon lubricant such as perfluoropolyether (PFPE), while the lower piston and the crankcase are lubricated with hydrocarbon lubricant. The engine enables 3D and time-resolved measurements of strain, stress, and temperature, as well as phase transformation, texture, and microstructure.

A prechamber sparkplug assembly includes a sparkplug, and a sparkplug housing having a prechamber tip. The sparkplug housing includes a plug bore centered on a longitudinal axis of the sparkplug housing and receiving the sparkplug, an inside radial wall extending around the plug bore, and an outside radial wall. A cooling cavity is formed between the inside radial wall and the outside radial wall. Coolant ports extend through the outside radial wall and fluidly connect to the cooling cavity to place the cooling cavity in fluid communication with a water jacket in a cylinder head.

A prechamber sparkplug assembly includes a sparkplug, and a sparkplug housing having a prechamber tip. The sparkplug housing includes a plug bore centered on a longitudinal axis of the sparkplug housing and receiving the sparkplug, an inside radial wall extending around the plug bore, and an outside radial wall. A cooling cavity is formed between the inside radial wall and the outside radial wall. Coolant ports extend through the outside radial wall and fluidly connect to the cooling cavity to place the cooling cavity in fluid communication with a water jacket in a cylinder head.

A method of improving corrosion resistance of a cylinder cover including a port that is an intake port or an exhaust port. The cylinder cover is configured such that an annular cooling water passage is formed between an inner peripheral surface of the port and a valve seat ring when the valve seat ring is inserted in the port. The method includes forming a weld overlay layer on each of sealed regions of the inner peripheral surface of the port by laser metal deposition using a welding material made of a nickel-based alloy, a copper alloy, stainless steel, or a titanium alloy, the sealed regions being positioned at both sides of the cooling water passage, respectively.