The invention relates to a nozzle needle (10) for a fuel injection device (100), in particular a fuel injector, comprising a nozzle needle tip (12) which is connected to a nozzle needle shaft (11). The nozzle needle tip (12) and the nozzle needle shaft (11) consist of different materials. According to the invention, the nozzle needle shaft (11) has a receiving area (20) formed by a blind bore (21) for the nozzle needle tip (12). The base (22) of the receiving area (20) forms an axial stop for the nozzle needle tip (12), and the nozzle needle tip (12) has an at least approximately constant diameter (d) within the receiving area (20), said diameter simultaneously forming the largest diameter of the nozzle needle tip (12).

A first metal powder is supplied to a substrate to form a beginning part of a clad layer. After the beginning part is formed, the second metal powder is supplied to the substrate. A concentration of at least one of Si, Ni, Mo, and Al in the first metal powder is lower than a concentration thereof in the second metal powder.

In a nozzle plate of the present invention, a part of fuel flowing out from a fuel injection port of a fuel injection device is atomized by colliding with an interference body, is rapidly bent in a flowing direction, and collides with the fuel that is flowing straight through a nozzle hole and an orifice to make the fuel that flows straight through the nozzle hole and the orifice turbulent. The orifice includes a corner portion which is defined by an outer edge portion of the interference body and has a pointed shape without roundness at a part of an opening edge. The corner portion makes an end portion of a liquid film of the fuel passing through the orifice into a pointed shape for ease of atomization by friction with air.

Nozzle and a method of making the same are disclosed. The method includes forming a material into a nozzle forming microstructured pattern comprising a plurality of nozzle hole forming features and planar control cavity forming features; forming at least one different material into a nozzle pre-form using the nozzle forming microstructured pattern, with the nozzle pre-form comprising a plurality of nozzle pre-form holes and sacrificial planar control cavities; and forming a nozzle from the nozzle pre-form, said forming the nozzle comprising removing enough of the at least one different material to remove the sacrificial planar control cavities so as to form a top surface of the nozzle pre-form into a top surface of the nozzle, and to form each of the nozzle pre-form holes into a nozzle through hole.

A first metal powder is supplied to a substrate to form a beginning part of a clad layer. After the beginning part is formed, the second metal powder is supplied to the substrate. A concentration of at least one of Si, Ni, Mo, and Al in the first metal powder is lower than a concentration thereof in the second metal powder.

A valve seat alloy having a clad layer made of Cu-based powder that contains Ni: 5.0% to 20.0%, Si: 2.4% to 4.0%, and Mo: 0% to 40.0%, wherein the valve seat alloy has aluminum content of 12% or less.

Nozzle and a method of making the same are disclosed. The method includes (a) providing a microstructured mold pattern defining at least a portion of a mold and comprising a plurality of replica nozzle holes and replica planar control cavities; (b) molding a first material into a nozzle forming microstructured pattern using the microstructured mold pattern, with the nozzle forming microstructured pattern comprising a plurality of nozzle hole forming features and planar control cavity forming features; (c) forming a second material into a nozzle pre-form using the nozzle forming microstructured pattern, with the nozzle pre-form comprising a plurality of nozzle pre-form holes and sacrificial planar control cavities; and (d) forming a nozzle from the nozzle pre-form, said forming the nozzle comprising removing enough of the second material to remove the sacrificial planar control cavities so as to form a top surface of the nozzle pre-form into a planar top surface of the nozzle, and to form each of the nozzle pre-form holes into a nozzle through hole.