MXPA98001254A - Head of cylinder composed of ceramic matrix reinforced with fiber and cylinder head link for an internal combustion engine - Google Patents

Abstract

The presentation relates to components of internal combustion engines and, more particularly, to a ceramic cylinder head or a reinforced ceramic matrix liner for internal combustion engine. The present invention solves the problems of failure due to thermal impact, damage from minor impacts, erosion, engine weight, and the like. The entire ceramic cylinder head or a fiber-reinforced ceramic matrix composite liner also includes a heat sink on the surface to maintain contact temperatures at a reasonable level. The head of the ceramic cylinder or headgear is for a car that can be placed under a car cover without damaging other vehicle systems.

Description

HEAD OF CYLINDER COMPOSED OF CERAMIC MATRIX REINFORCED WITH FIBER AND CYLINDER HEAD LINK FOR AN INTERNAL COMBUSTION ENGINE TECHNICAL FIELD This invention relates to the components of internal combustion engines and, more particularly, to a ceramic cylinder head or fiber-reinforced ceramic matrix liner for the internal combustion engine comprising a cylinder head of composite ceramic matrix reinforced with structural fiber.

BACKGROUND OF THE INVENTION A typical internal combustion engine comprises an engine block containing one or more cylinders in which the pistons move up and down as a result of fuel combustion therein. The cylinders are covered and closed by a cylinder head 10 as shown in Figures 1 and 2. Combustion of the fuel under compression releases energy such as movement and heat. Consequently, the engine parts tend to get very hot. To avoid damage to the metal due to overheating and lubrication decomposition problems and possible motor clutch from excessive thermal expansion of the parts, the heat must be driven out to limit the operating temperature of the motor to the standards of design. This is usually done in one of two ways. As shown in Fig. 1, the cylinder head 10 can have a water jacket 12 integrated therein where the water jacket 12 is connected by means of the connecting pipes 30, 32 to the water circulating through the block and a radiator cooled with air. As shown in Fig. 2, the cylinder head 10 may incorporate fins 14 that provide a large surface area to radiate the heat directly to the air passing through it. Motorcycles, lawnmowers and the like, tend to use the fins 14 while the automobile and truck engines are favorable for a water jacket 12 due to the high heat loads generated in their operating environment in conjunction with the requirements of temperature under the permissible cover. In addition, the water jacket 12 provides a heat source for vehicle heating, ventilation and the air conditioning system (HVAC). Therefore, it is an object of the present invention to provide a cylinder head or headliner of a materal composed of fiber-reinforced ceramic matrix that includes the arrangement for reducing its temperature level on the outer surface thereof.

It is another object of the present invention to provide a ceramic cylinder head or headliner made of a composite ceramic matrix material reinforced with structural fiber for a car that can be placed under the cover of a car without damaging other vehicle systems. from radiated heat. It is another object of the present invention to provide a ceramic cylinder head or head jacket made of a ceramic matrix composite material reinforced with structural fiber for an automobile that provides or takes into account the hot water of a passenger compartment that heats up the system. Other objects and benefits of this invention will become apparent from the following description when read in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE INVENTION The following objects have been achieved by the ceramic cylinder head and the ceramic headliner for an internal combustion engine of the present invention comprising a cylinder head made of a generic fiber system cilocado through a resin of pre-ceramic in its ceramic state and means to transfer heat from the cylinder head.

In the preferred embodiment, the means for transferring heat from the cylinder head will depend on the specific application for which the motor is designed. Motor vehicle applications typically include the use of a liquid cooling system to remove excess heat from the head which also provides a heat source for the passenger cabin heating system, while the engines of lower service are cooled with air typically. In one embodiment, the means for transferring heat from the cylinder head comprises radiating fins formed on the upper surface of the cylinder head to transfer heat to the air surrounding the fins. In another embodiment, the means for transferring heat from an upper surface of the cylinder head comprises a metalic heat sink attached to the upper surface, the heat sink including radiant alters to transfer heat to the air surrounding the fins. In an embodiment for producing hot water as a sub-product, the means for transferring heat from the cylinder head comprises a metal jacket of water formed on the upper surface wherein the water jacket has an inlet pipe and an outlet pipe for passing engine coolant or some other fluid used in the passenger compartment heating system. This mode can be formed directly on the ceramic cylinder head.

The fourth embodiment is a FRCMC cylinder head sleeve locked for use in a cylinder head cooled with water. The fifth embodiment is a mechanically trapped FRCMC cylinder head jacket for air cooled cylinder head applications.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a simplified cross section of a cylinder head of the prior art with a water jacket incorporated therein, representative of typical automotive applications. Figure 2 is a simplified cross-section of a prior art cylinder cavity with air cooling incorporated therein, typically in lower duty engine applications. Figure 3 is a simplified cross section of a ceramic cylinder head with integral air cooling fins incorporated therein in accordance with a first embodiment of the present invention. Figure 4 is a simplified cross section of a ceramic cylinder head with metal air cooling fins attached thereto as an aggregate article in accordance with a second embodiment of the present invention.

Figure 5 is a simplified cross section of a ceramic cylinder head incorporating a metallic water jacket formed in accordance with a third embodiment of the present invention. Figure 6 is a simplified cross-section of a ceramic cylinder head incorporated within a metal water jacket formed in accordance with a fourth embodiment of the present invention. Figure 7 is a simplified cross section of a ceramic cylinder head incorporated within a metal water jacket formed in accordance with a fifth embodiment of the present invention.

BEST WAYS TO CARRY OUT THE INVENTION In one embodiment of the present invention as illustrated in Fig. 3, a cylinder head 10 'is formed of a material 1 composed of ceramic matrix reinforced with structural fiber (FRCMC). In particular, the cylinder head 10 'can be made from a ceramic fiber composite material reinforced with structural fiber comprising a polymer-derived ceramic resin or a cementing resin that has been modified to emulate the polymer composite processing techniques that have fibers from a generic fiber system placed through them. The preferred FRCMC material employs any of the commercially disposable pre-ceramic resins such as silicon-carboxyl resin (sold by Allied Signal under the trade name Blackglas), alumina silicate resin (sold by Applied Poleramics under the designation CO product) "), or monoaluminum phosphate resin (also known as monoaluminum phosphate) combined with a generic fiber system such as, but not limited to, alumina, Altex, Nextel 312, Nextel 440, Nextel 510, Nextel 550, Nitride silicon, silicon carbide, HPZ, graphite, coal and peat To add additional hardness qualities to the material, the fiber system can be first coated up to 0.1-5.5 microns thick with an interface material such as, but not limited to , carbon, silicon nitride, silicon carboxyl, silicon carbide or boron nitride or a layered combination of one or more of the above interfacial materials. The interphase prevents the resin from adhering directly to the fibers of the fiber system. Therefore, when the resin is converted to a ceramic matrix, there is a slight play between the ceramic and the fibers imparting the desired qualities to the final FRCMC material. In addition, it is recommended that the head surface of the FRCMC head or the head jacket facing the cylinder orifice of the combustion environment can be shielded with a water-resistant coating to resist corrosive combustion materials by means of flame resistant coatings. erosion commercially available, such as alumina powder sprayed with plasma or physical vapor deposition of a titanium nitride or, with conventional plasma spray techniques and materials identified in the co-pending application entitled REDUCING WEAR BETWEEN STRUCTURAL FIBER REINFORCED CERAMIC MATRIX COMPOSITE AUTOMOTIVE ENGINE PARTS IN SLIDING CONTACTING RELATIONSHIP of the inventors herein, serial number PCT / US96 / 11771 filed on the same date as the present one. In a first embodiment for coating the head surface FRCMC or headgear that confronts the combustion environment with a wear resistant coating, a woven mat of woven or non-woven fabric is employed. In this embodiment, the contact surfaces of the composite component of ceramic matrix reinforced with structural fiber are covered with an erosion resistant coating that is tightly bonded to the wearing surface of the FRCMC structures. For this purpose, the erosion resistant coating preferably comprises Mullite (ie, alumina silicate AI2Si), alumina (ie, AI2O3) or equivalent, applied by means of a plasma spray, generally in accordance with well-known techniques. those with experience in the technique. The erosion resistant coating is applied as follows. Before the application of the erosion resistant coating, all holes for spark plugs, valves, piston pins are machined. Commercial grade diamond cutting tools are recommended for this purpose. Any other machining as will be described later is also done at this point. Upon completion of the machining process, if any, all sharp edges on the surface of the part are recessed using diamond paper. If the part has been machined, it is placed in an oven for a suitable time and temperature to ensure the "burning" of any cutting lubricants used in the machining process. (Typically 2 hours at 371.1 ° C although it depends on the lubricant). The key is to get the erosion-resistant coating to join the FRCMC structure. If the surface of the FRCMC structure is not properly prepared, the erosion-resistant coating can simply be peeled off and does not provide long-term protection. In the preferred approach, the surface of the FRCMC structure is lightly blasted with lightly grit blasting to form small pieces within the ceramic matrix of the FRCMC structure. It is also considered that cleaning with a light cutting blast jet exposes capillaries or filamentary crystalline growths on the exposed fiber of the generic fiber system which can be held by the erosion resistant roof and adhered to it. The typical blasting blast cleaning that has proven to be successful is 100 grit @ 20 PS I. According to a second possible approach, the surface of the FRCMC structure can be provided with a series of thin, hollow, similar, thin "threaded" similar grooves of a nut or bolt, within which the erosion resistant coating can lock. . Essentially, the surface is scored to provide a chopped surface instead of a uniform surface. The depth, width, and spacing of the grooves is not critical and can be determined for each part or component without undue experimentation. In general, the grooves must be closely spaced to minimize any large uniform areas of the surface where there is a potential for the erosion-resistant coating to lose its adhesion and release. Therefore, overriding would be preferable to surface undercutting with the exception that the overriding requires the application of additional wear material to provide a uniform wear surface after final grinding. The grooves must be hollow to provide a mechanical locking area for the erosion-resistant coating without reducing the structural strength of the underlying FRCMC structure to any appreciable extent. After the preparation of the surface, the part is cleaned using dry and clean compressed air and then charged into a suitable support accessory for the plasma spray process. Direct air blowers are used to cool the opposite side of the part while applying the erosion resistant coating.

The erosion resistant coating sprayed with plasma is then applied using a deposition rate set at 5 grams per minute or more. The speed of the support fixture, the speed of movement of the plasma gun through the surface and the spray width are set to achieve a spiral spray pattern with 50% overlap. The spray gun is fixed in relation to the surface sprayed from 0.254 to 7.62 cm. The tam, particle years used for this process vary from 170 to 400 mesh. Sufficient material is applied to allow finishing machining. After the application of the erosion-resistant coating, the surface is laid with diamond paper or a suitable forming tool (commercial grade diamond tools are recommended) to achieve the final surface contour. In an alternative embodiment, the erosion-resistant material in powder form can be dispersed within the matrix material (i.e., the resin) before forming the component for improved wear resistance. Alternatively, the plasma spray coating can be applied and then the part with the adhering erosion resistant coating can be re-infiltrated with the pre-ceramic polymer resin and then converted to a ceramic state. The result is an additional hardening of the coating by essentially incorporating the coating within the combined ceramic matrix composite formed from the combination of the FRCMC and a reinforced monolithic wear coating of ceramic matrix integrally joined by the common ceramic matrix. In addition, the surface of the FRCMC head or head cap facing the combustion environment may be coated with a wear resistant coating to resist corrosive combustion materials by means of erosion resistant coatings, such as alumina powder plasma spray or physical vapor deposition of a titanium nitride or, with conventional plasma spray techniques and materials identified in the co-pending application entitled METHODS AN D APPARATUS FOR MAKI NG CERAMIC MATRIX COMPOSITE LINED AUTOMOTIVE PARTS AN D FI BER REI N FORCED CERAMIC MATR IX COM POSITE TO UTOMOTI VE PARTS of the inventors herein, serial number PCT / US96 / 1 1772 filed on the same date as this application. A first aspect is a method for forming a metal part having a rupture-resistant ceramic liner comprising the steps of forming a metal part having a mating surface for receiving the liner; forming a lining of a ceramic material containing pores; filling the pores with a pre-ceramic polymer resin; igniting the saturated liner of pre-ceramic polymer resin at a temperature and for a time (designed by the resin manufacturer) that converts the resin into a ceramic within the pores; and, join the ceramic lining to the mating surface of the metal part. In one embodiment, the step of forming the lining of a ceramic material containing pores comprises pouring an inexpensive castable paste into a mold in a linear fashion, igniting the molded paste material for a time and at a temperature which makes it a manageable pre-ceramic form, remove the pre-ceramic form from the mold and ignite the pre-ceramic form for a time and at a temperature that turns it into a ceramic form containing pores formed by degassing. And, the step of filling the pores with a polymer-derived ceramic resin comprises placing the liner within a bath containing a liquid pre-ceramic polymer resin until the pores are saturated with the resin. Preferably, the resin is silicone-carboxyl resin (sold by Allied-signal under the trade name Blackglas). In a second embodiment, the step of forming the lining of a ceramic material containing pores comprises placing a fiber preform within a mold of lining form to occupy 30% up to 60% amp.; of the mold volume, forcing a pre-ceramic polymer resin through the preform to fill the remaining volume of the mold with the liquid pre-ceramic polymer resin, ignite the mold for a time and at a temperature that cionvertise in a manageable pre-ceramic form, remove the pre-ceramic form from the mold, and ignite the pre-ceramic form for a time and at a temperature that convert the liquid pre-ceramic polymer resin into a composite form of ceramic matrix containing pores formed by degassing. Preferably, the liquid pre-ceramic polymer resin is silicon-carboxyl resin, for example, Blackglas. A second aspect of the present invention is a method for forming a metal part having a rupture resistant ceramic liner comprising the steps of forming a liner of a ceramic material containing pores; filling the pores with a pre-ceramic polymer resin; ignite the saturated liner with the pre-ceramic polymer resin at a temperature and for a time (as designated by the resin manufacturer), which converts the resin into a ceramic with pores; placing the liner inside a mold for the metal part with the engaging surface of the liner facing into a portion of the mold to be occupied by the metal forming the part; and, fill the mold with the molten metal to form the part. As in the first aspect, the step of forming the lining of a ceramic material containing pores can comprise any approach described above. And, the step of filling the pores with a polymer-derived ceramic resin again comprises placing the liner within a bath containing a liquid pre-ceramic polymer resin until the pores are saturated with the resin; ignite the liner saturated with the pre-ceramic polymer resin at a temperature and for a time that converts the resin into a ceramic within the pores. In all cases where the pores formed by degassing are filled, it is preferred to repeat the pore filling and the reheating process several times to virtually completely remove the pores of the final product. In another aspect of the present invention, a method for making an automotive part composed of fiber reinforced ceramic matrix comprising the steps of forming a preform in the form of a part from fibers of a generic fiber system is described. which can be used in fiber-reinforced ceramic matrix composites; placing the preform in a cavity of a mold having the shape of the part; forcing a polymer-derived ceramic resin through the cavity and saturating the preform; heating the mold at a temperature and for a time associated with the polymer-derived xceramic resin which transforms the saturated preform with liquid polymer-derived ceramic resin into a polymer composite part; remove the polymer composite part of the mold; and, igniting the polymer composite part in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin that transforms the polymer-derived ceramic resin into a ceramic so that the polymer composite part it is transformed into a composite part of ceramic matrix reinforced with fiber.

Preferably, the method also includes the steps of submerging the composite part of fiber reinforced ceramic matrix containing pores formed by degassing during ignition within a bath of the polymer resin derived from liquid polymer to fill the pores with the resin ceramic derived from liquid polymer; igniting the composite part of fiber-reinforced ceramic matrix in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin which transforms the polymer-derived ceramic resin into the pores within a ceramic; and repeat this process until the pore density within the composite part of ceramic matrix reinforced with final fiber is less than a preset percentage that reaches the maximum strength for the part. The preferred method is also adaptable to forming hollow parts such as engine multiples using the steps of forming a first preform in the form of a lower portion of the manifold from fibers of a generic fiber system that is used in matrix composites. ceramic reinforced fiber; placing the first preform in a cavity of a first mold having the shape of the lower portion of the manifold; forcing a ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturate the first preform; heating the first mold at a temperature and for a time associated with the polymer-derived ceramic resin that transforms the first saturated preform with ceramic resin derived from liquid polymer into a first polymer composite part; remove the first polymer composite part from the mold; forming a second preform in the form of an upper portion of the manifold from fibers of a generic fiber system; placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold; forcing the ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturate the second preform; heating the second mold at a temperature and for a time associated with the polymer-derived ceramic resin which transforms the second saturated preform with ceramic resin derived from liquid polymer into m a second part composed of polymer; remove the second part composed of polymer from the mold; adjusting the first polymer composite part and the second polymer composite part together along engaging edges to form the manifold as a hollow duct part; and igniting the polymer composite manifold in an atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin that transforms the polymer-derived ceramic resin into a ceramic so that the multiple compound of The polymer is transformed into a multiple matrix of fiber-reinforced ceramic matrix and the upper portion and the lower portion are fused together along their coupling edges.

The pores formed by degassing are preferably sealed in the manner described above to give maximum resistance to the resulting manifold and seal any leakage that may exist along the coupling edges. When the mulqile is an exhaust manifold to be filled internally with a ceramic foam catalyst substrate structure the required process and tooling can be greatly simplified prior to the step of placing the second preform into a cavity of a second mold having the form of the upper portion of the manifold further including the steps of, placing the first preform as part of a wall defining the cavity of the second mold; and placing the structure of its ceramic foam catalyst substrate into the first preform whereby the first preform and the ceramic foam catalyst substrate structure in combination form the part of the cavity of the second wall. Referring to Figure 3, the fins 14 of the collet head 10 'are formed integral with the cylinder head 10' itself, thereby providing an individual FRCMC unit. Additionally, an erosion-resistant coating 28 is applied by means of plasma spray techniques, to the side that confronts the combustion of the head to improve the strength capabilities. The fins 14 are not as resistant to breakage as the metal fins. Therefore, this mode is not preferred for most applications.

In the cylinder head 10 'of FIG. 4, the fins 14 are also used; but, in this case, they are part of a metallic heat sink 16 that is sleeved with bolts on the top of the cylinder head using bolts 18 used to secure the cylinder head 10 'to the engine block. The heat sink 16 and its fins 14 can be welded steel, cast aluminum or iron. Or similar, as is most appropriate for the particular application. Additionally, an erosion-resistant coating 28 is applied, by means of plasma spray techniques, to the side facing the combustion of the ceramic head to improve the strength capabilities. This mode is preferred for small motor applications such as garden and pruning equipment. There are three preferred embodiments for the application of the present invention for large power plants such as those found in motorized vehicles and those used as a source of stationary energy. The first one is illustrated in Fig. 5. The cylinder head 10 'is made of metal having a metal water jacket 12 cast on it as well as an integrally cast head liner 1 1. The water jacket 12 has an inlet pipe 30 and an outlet pipe 32 in the usual manner. Since the cylinder head liner 1 1 is ceramic, it can be subjected to the molten metal during the casting process of the water jacket without prejudice. Therefore, in a preferred construction approach, the headliner 11 would first be made. The head jacket 11 would be placed inside a mold for the water jacket 12 as part of the walls of the mold cavity. By pouring the molten metal into the mold, the water jacket 12 would be cast directly onto the head sleeve of the cylinder head 1 1 which molds to the contact surface for maximum structural integrity. Additionally, an erosion resistant coating 28 is applied, by means of plasma spray techniques, to the side facing the head / head jacket combustion to improve the strength capabilities. The second of the preferred embodiments is illustrated in Figure 6. The head cap of the cylinder head 1 1 'is made in the manner described above. A separate conventional metal head 10"including a water jacket 12 is manufactured using the current state of the field techniques, with the exception that the region of the combustion chamber of the head is oversized to the left with an internal contour which engages the lateral contour facing the non-combustion chamber of the FRCMC head cap 1 1. The FRCMC head cap is then adhesively bonded in place using commercially available high temperature or silicone adhesive adhesives 34 which include, but not limited to, joint material PERMATEX U LTRA COPPE R. Additionally, an erosion resistant coating 28 is applied, by means of plasma spray techniques, to the side facing the combustion of the FRCMC headliner to improve the resistance capacities The third of the preferred embodiments is illustrated in Figure 7. The head cover of the cylinder head 1 1 'It is made in the manner described above. A separate conventional metal head 10"includes a water jacket 12 is manufactured using the current state of the field techniques with the exception that the region of the combustion chamber of the head is oversized to the left with an internal contour that couples the lateral contour facing the non-combustion chamber of the FRCMC 1 1 'headgear The F RCMC headgear is then mechanically trapped between the indro cylinder block (not shown) and the conventional metal head 1022 by the use of bolts In addition, an erosion-resistant coating 28 is applied, by means of plasma spray techniques, to the side facing the combustion of the FRCMC head / jacket to improve the strength capabilities.

Example: Manufacture of a FRCMC Head Shirt 1 . Manufacture or purchase a headliner preform of the required size (there are several U.S. vendors that manufacture preforms for composite applications) from fibers such as, but not limited to, alumina, Altex, Nextel 312, Nextel 440, Nextel 510, Nextel 550, silicon nitride, silicon carbide, HPZ, graphite, carbon, and peat. The preform must be made so that when it is loaded in the mold tool, it covers between 30% and 70% of the open volume inside the closed tool. 2. The preform then has a fiber interface coating applied to it according to the best industry practices. The assignee of this application, Northrop Corporation, currently has a number of patents on the application of interface coatings, including U.S. Patent No. 5,034,181, entitled APPARATUS FOR METHOD OF MANUFACTURING PREFORMS; U.S. Patent No. 5,110,771, entitled METHOD OF FORMING A PRECRACKED FIBER COATING FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES; U.S. Patent No. 5,275,984, entitled FIBER COATING OF UNBONDED MULTI-LAYERS FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES; U.S. Patent No. 5,162,271, entitled METHOD OF FORMING A DUCTILE FIBER COATING FOR TOUGHENING NON-OXIDE CERAMIC MATRIX COMPOSITES; and U.S. Patent No. 5,221,578, entitled WEAK FRANGIBLE FIBER COATING WITH UNFILLED PORES FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES, the teachings of which are incorporated herein by reference. Likewise, Allied Signal or Sinterials are commercial companies that apply an interface coating as a sold service. 3. The shaped head preform is then placed in the cavity in the form of a head cap of a mold and the mold closed and sealed around it. 4. The lower feed holes in the mold are connected by means of flexible tubing with a valve to a container containing Blackglas resin. The upper ventilation hole is connected by means of transparent flexible pipe with a valve to a vacuum source. Both valves are initially open to allow the resin to be sucked through the mold. 5. The container with Blackgras resin is pressurized above 1.05 kg / cm2, ie above atmospheric pressure, to create a positive pressure that tends to force the resin through the mold. When the resin is flowing through the mold without air bubbles present in the pipe on the vacuum side (outlet), both valves are closed. 6. The mold with the enclosed preform and the resin mixture is then heated according to the following cycle: A) Raise from room temperature to 65.5 ° C to 2.7 ° / minute. B) Keep at 65.5 ° C for 30 minutes. C) Raise to 1 .7 ° / minute to 148.8 ° C. D) Maintain at 148.8 ° C for 60 minutes. E) Cool to 1 .2 ° / minute until the temperature is below 60 ° C to demold the part.

It should be noted that there is a variety of warming cycle definitions that will create the usable tooling and the foregoing is by way of example only and is not intended to be exclusive. 7. Upon cooling the mold, the mold is disassembled and the composite polymer component removed from the mold by pyrolysis. NOTE: The previous seven steps identify a Resin Transfer Molding (RTM) approach to prepare the polymer composite component. Other applicable approaches to create the same part are Close-to-Hand or Short-Fiber Injection. these are Polymer Compound Manufacturing Techniques to be included within the scope and spirit of the present invention and the appended claims thereto. These different techniques are not claimed to be inventive of the present inventors in and of the same. 8. The polymer composite component is then pyrolyzed. In this regard, the manufacture of a sealable container, such as a stainless steel box, capable of withstanding 1037.7 ° C for the pyrolysis cycle in a standard oven is required. In the alternative, an inert gas oven could be used if available. The box must have two pipe connections, one at the bottom and one at the top to allow the box to be flooded with an inert gas. In this example, the sleeve is placed in the box, the box placed in a standard oven, stainless steel pipe is connected to the lower connector on the box and for a supply of high purity argon. Of course, an alternate inert gas could be used. The argon is allowed to flow in the box, and out of the upper vent at a rate of 5-10 SCFH for the entire heating cycle, thus ensuring that the sleeve is fully bathed in an inserted environment. The oven is closed and ignited on the following base: A) Raise the temperature to 148.8 ° C to 223 ° / hour B) Raise to 482.2 ° C to 43 ° / hour C) Raise to 760 ° C to 20 ° / hour D ) Raise to 871. 1 ° C to 50 ° / hour E) Keep at 871 .1 ° C for 4 hours F) Raise to 25 ° C to -1 '5 ° / hour Again, there is a variety of different heating schedules of the present, given by way of example only, which will produce the usable tooling. 9. Upon cooling, the head jacket is removed from the furnace and the box is submerged in a Blackglas resin bath for a sufficient time to allow all air to be removed from a head jacket (typically 5 minutes or more). A vacuum infiltration can also be used for this stage. 10. Steps 8 and 9 may be repeated, if desired, until the percentage of pores formed in the resin by degassing is minimized and the strength of the part is maximized (typically five times). eleven . The head sleeve is now ready for the machining of the pre-wear coating application. At this time and before the application of the wear coating, all holes (spark plugs, valves etc.) are machined (commercial grade diamond cutting tools are recommended). Upon completion of machining processes, all sharp edges on the surface of the headliner are recessed using diamond paper. 12. The head jacket is placed in an oven for a time and at a suitable temperature to ensure "burning" of any cutting lubricants used in the machining process. (Typically 2 hours @ 371 .1 ° C, but depends on the lubricant). 1 3. The side of the combustion chamber of the head jacket is washed with shot blast using a shot and pressure suitable to remove any loose matrix material and expose the fibers within the FRCMC. (Typically 100 grit @ 20 PSI). 14. The head sleeve is cleaned using dry and clean compressed air. 15. The head jacket is then loaded into a support accessory for the plasma spray process. 16. Direct air blowers are used to cool the side of the chamber without combustion of the head jacket. 17. The wear coating sprayed with plasma is then applied using a deposition rate of 5 grams per minute or more. The rotational speed of the support fixture, the speed of movement of the plasma gun across the surface and the width of the spray are set to achieve a spiral spray pattern with 50% overlap. The spray gun is fixed relative to the surface sprayed from 0.254 to 7.62 cm. The particle sizes used for this process vary from 170 to 400 mesh. Sufficient material is applied to allow finishing machining. 18. After the application of the wear coating, the combustion chamber area of the sleeve head is smoothed with diamond paper or a suitable forming tool (recommended commercial grade diamond tools) the final internal contour. 19. The head sleeve can then be attached to or cast into its coupling as appropriate to the particular embodiment being implemented. After installation with its coupling, the block coupling surface of the head sleeve is machined flat. In the case of the embodiment of Figure 7, the head sleeve is machined flat separately since it is not physically attached to the metal head and the water jacket.

Claims (17)

1. CLAIMS 1 . A ceramic cylinder head for an internal combustion engine comprising: a) A ceramic cylinder head for an internal combustion engine comprising: a) a cylinder head comprised of a generic fiber system that has been placed across thereof a pre-ceramic polymer resin in its ceramic state where the pre-ceramic polymer resin consists of a polymer resin derived from ceramic; and b) means for transferring heat away from an upper surface of the cylinder head to maintain the cylinder head below a threshold temperature. The ceramic cylinder of claim 1, wherein the means for transferring heat away from an upper surface of the cylinder head comprises: radiating fins formed on the upper surface of the cylinder head to transfer heat to the cylinder head. air that surrounds the fins. The ceramic cylinder of claim 1, wherein the means for transferring the heat from an upper surface of the cylinder head comprises: a metallic heat sink attached to the upper surface, the heat sink including radiating fins for transferring the heat towards the air that surrounds the fins. The ceramic cylinder of claim 1, wherein the means for transferring the heat from an upper surface of the cylinder head comprises: a metal jacket of water formed on the upper surface, the water jacket having a pipe of inlet and an outlet pipe to pass the engine coolant through it. The ceramic cylinder of claim 1, wherein the means for transferring the heat from an upper surface of the cylinder head comprises: a metal jacket of water adhesively bonded or mechanically bonded on the upper surface, the water jacket It has an inlet pipe and an outlet pipe to pass the engine coolant through it. The ceramic cylinder of claim 1, wherein the means for transferring the heat from an upper surface of the cylinder head includes means for heating a fluid used in the passenger compartment heating system. The ceramic cylinder of claim 1 and further comprising: an erosion resistant coating positioned on a side that confronts the combustion of the cylinder head so that the resistance capabilities of the cylinder head are improved. 8. A ceramic cylinder head for an internal combustion engine comprising: a) a cylinder head made of a generic fiber system having a pre-ceramic polymer resin placed therein in its ceramic state Count the pre-ceramic polymer resin consists of a polymer resin-derived ceramic; and b) a metal water jacket on an upper surface of the cylinder head, the water jacket having an inlet pipe and an outlet pipe for passing the engine coolant therethrough to keep the cylinder head below of a threshold temperature. 9. The ceramic cylinder head of claim 8 and further comprising: an erosion-resistant coating on one side that confronts the combustion of the cylinder head so that the resistance capabilities of the cylinder head are improved . 10. A ceramic cylinder head for an internal combustion engine comprising: a) a cylinder head made of a generic fiber system having a pre-ceramic polymer resin in its ceramic state therein; wherein the pre-ceramic polymer resin consists of a polymer resin derived from a polymer; and b) a metal jacket of water adhesively bonded or mechanically bonded on the upper surface, the water jacket having an inlet pipe and an outlet pipe for passing the engine coolant therethrough to maintain the cylinder head below a threshold temperature. eleven . The ceramic cylinder head of claim 10 and further comprising: an erosion resistant coating on one side that confronts the combustion of the cylinder head so that the resistance capabilities of the cylinder head are improved. 12. A cylinder head lined with ceramic for an internal combustion engine comprising. a) a cylinder head liner having a combustion facing side and which is of a generic fiber system having a pre-ceramic polymer resin placed therein in its ceramic state where the polymer resin of Pre-ceramic consists of a ceramic resin derived from polymer below a threshold temperature; and, b) a metal cylinder head positioned on an upper surface of the cylinder head liner, the metal cylinder head including means for transferring heat away from the upper surface of the cylinder head liner to maintain the cylinder head below a threshold temperature. 13. The ceramic-lined cylinder head of claim 12, wherein the means for transferring heat from the upper surface of the cylinder head liner comprise: radiating fins formed on an upper surface of the metal cylinder head to transfer the heat towards the air that surrounds the fins. The ceramic-lined cylinder head of claim 12, wherein the means for transferring heat from the upper surface of the cylinder head liner comprise: a heat sink attached to the top surface of the metal cylinder head, The metallic heat sink includes radiating fins to transfer heat to the air surrounding the fins. The ceramic-lined cylinder head of claim 12, wherein the means for transferring the heat from the upper surface of the cylinder head liner comprise: a metal water jacket formed in the metal cylinder head, the jacket of water that has an inlet pipe and an outlet pipe to pass the engine coolant through it. 16. The cylinder head lined with ceramic of claim 12, wherein: means for transferring heat from the upper surface of the cylinder head liner include means for heating a UU'TQo used in the compartment heating system of the passenger 17. The cylinder head lined with ceramic of claim 12 and further comprising: an erosion-resistant coating on one side that confronts the combustion of the cylinder head so that the resistance capabilities of the cylinder head are improved. .