Aluminum alloys having improved properties are provided. The alloy includes about 8 to about 12 weight percent silicon, about 0.5 to about 1.5 weight percent copper, about 0.2 to about 0.4 weight percent magnesium, 0 to about 0.5 weight percent iron, about 0.3 to about 0.6 weight percent manganese, 0 to about 1.5 weight percent nickel, and 0 to about 0.5 weight percent zinc. Aluminum may be present in an amount between about 80 and 91 weight percent. The alloy may include about 0.1 to about 0.5 weight percent each of trace elements such as titanium, vanadium, and/or zirconium, and up to about 0.25 weight percent of all other trace elements. In addition, the alloy may contain about 0.03 to about 0.1 weight percent of strontium, sodium, and/or antimony, and up to 5 ppm phosphorus. Also disclosed is a high pressure die cast article, such as an engine block.

An internal combustion engine includes an engine block, a piston, a cylinder head, and a valve train. The engine block includes a cylinder block including a cylinder bore and a crankcase defining a crankcase chamber with a crankshaft positioned within the crankcase chamber. The piston is coupled to the crankshaft and configured to reciprocate within the cylinder bore. The cylinder head is coupled to the cylinder block. The valve train includes a camshaft, a first and second pushrod, a first and second rocker arm, an exhaust valve housed, and an intake valve. The first rocker arm, the second rocker arm, the exhaust valve, and the intake valve each include at least a layer of a low friction material. The first and second pushrod each pass through a pushrod seal to prevent fluid from reaching the rocker chamber to fluidly isolate the rocker chamber from the crankcase chamber.

A sliding mechanism of the present invention includes a cylinder bore having a thermally sprayed iron-based coating and includes a piston with a piston ring covered with a hard coating composed mainly of carbon. The thermally sprayed coating has diamond abrasive grains. An area ratio of the diamond abrasive grains to a surface of the thermally sprayed coating is 0.3 to 1.8%, which enables suppressing wear of the piston ring having the hard coating composed mainly of carbon.

An internal combustion engine comprising: a combustion chamber surrounded by at least an inner wall of a cylinder bore, a cylinder head, a valve and a piston, and a coating layer arranged on at least part of the inner wall of the combustion chamber, wherein the thermal conductivity of the coating layer is, at room temperature, lower than the thermal conductivities of the cylinder block, the cylinder head, the valve and the piston, the thermal conductivity of the coating layer is reversibly increased along with a rise in the temperature of the coating layer, and wherein the heat capacity per unit area of the coating layer is more than 0 kJ/(m.sup.2.Math.K) and 4.2 kJ/(m.sup.2.Math.K) or less.

A ferritic aero diesel engine. The ferritic aero diesel engine includes an iron crankcase, a steel crankshaft and eight steel piston assemblies. The iron crankcase has a flat, horizontally opposed eight cylinder arrangement with a first set of cylinder walls defining a first set of cylinders in a first bank and a second set of cylinder walls defining a second set of cylinders in an opposed second bank. The steel crankshaft is rotatably mounted at least partially within the iron crankcase. Each of the steel piston assemblies of the plurality of steel piston assemblies is received within a respective cylinder of the iron crankcase and is coupled to the steel crankshaft. The first and second sets of cylinder walls have a minimum wall thickness of between approximately 4.8 and 5.2 mm.

The present disclosure relates to a manufacturing method of high-strength flake graphite cast iron, the high-strength flake graphite cast iron manufactured by the method, and an engine body including the cast iron, and more particularly, to flake graphite cast iron and a manufacturing method thereof, wherein the flake graphite cast iron has a uniform graphite shape and low probability of forming chill and has high tensile strength of at least 350 MPa and excellent workability and fluidity by controlling the content of manganese (Mn) and a trace of strontium (Sr), which are included in the cast iron, within a specific ratio.

The present invention provides an engine cover that can be manufactured easily and at a lower cost and has an attachment member that is high in quality and may not easily fall off. The engine cover has a cover body made of urethane foam, a skin layer disposed on a surface of the cover body, and an attachment member made of an elastic body and integrally molded with the cover body. The attachment member has a recess into which an attachment pin provided to project from an engine member is fitted, and a sealing portion that is provided to project at least one of the opening end surface of the recess and the side surface of the opening end part of the recess and that suppresses entry of a foamed urethane resin material that forms the cover body into the recess during integral molding.

To provide a surface structure of an aluminum-based member which can further improve heat insulating properties and heat shielding properties of the aluminum-based member. In an aluminum-based member 1 containing at least a silicon composition, a porous oxide film 2 is provided on a surface of the aluminum-based member 1, and the oxide film 2 is constituted to have at least a pore 2a extending from the surface toward an inside in a thickness direction of the oxide film 2 and a void 3a present inside the silicon composition 3 extending in a direction substantially orthogonal to the thickness direction of the oxide film 2.

A cylinder head assembly for an internal combustion engine includes a cast cylinder head defining a combustion chamber and fabricated from a first material, and an internal support structure at least partially encapsulated within the cast cylinder head. The internal support structure is fabricated from a thermal strain and fatigue resistant second material, different from the first material, such that during engine operation, thermal and mechanical loads are transferred to the internal support structure to reduce combustion chamber displacement. The internal support structure and the cylinder head are bonded via a hot isostatic pressing (HIP) process to eliminate internal porosity and gaps therebetween.

An engine for a vehicle. The engine includes a cast engine block having a hybrid insert disposed in a fastener bore having rolled internal threads. The hybrid insert includes an internal surface having cut inner diameter (ID) threads and an external surface having rolled outer diameter (OD) threads. The rolled OD threads of the hybrid insert are received in the rolled internal threads of the fastener bore. The hybrid threaded insert may include a bi-metal in which the ID threads are formed of one metal alloy and the OD threads are formed of another metal alloy. Alternatively, the external surface of the hybrid insert may define locking features and the engine block is cast onto these locking features, thereby locking the hybrid insert to the engine block.