US2620530A - Manufacture of pistons - Google Patents

Manufacture of pistons Download PDF

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Publication number
US2620530A
US2620530A US166900A US16690050A US2620530A US 2620530 A US2620530 A US 2620530A US 166900 A US166900 A US 166900A US 16690050 A US16690050 A US 16690050A US 2620530 A US2620530 A US 2620530A
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United States
Prior art keywords
ring
mold
piston
metal
ferrous metal
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Expired - Lifetime
Application number
US166900A
Inventor
Sulprizio Lucelio
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United Engine and Machine Co
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United Engine and Machine Co
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Filing date
Publication date
Priority claimed from US576592A external-priority patent/US2608735A/en
Application filed by United Engine and Machine Co filed Critical United Engine and Machine Co
Priority to US166900A priority Critical patent/US2620530A/en
Application granted granted Critical
Publication of US2620530A publication Critical patent/US2620530A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/0009Cylinders, pistons
    • B22D19/0027Cylinders, pistons pistons
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B5/00Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
    • F16B5/10Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of bayonet connections
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49229Prime mover or fluid pump making
    • Y10T29/49249Piston making
    • Y10T29/49256Piston making with assembly or composite article making
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12486Laterally noncoextensive components [e.g., embedded, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736Al-base component
    • Y10T428/1275Next to Group VIII or IB metal-base component
    • Y10T428/12757Fe

Definitions

  • This invention relates to the manufacture of pistons and the like and particularly to pistons made of aluminum or an aluminum base alloy and which are employed in engines which operate, for example, on the Otto or diesel cycle.
  • a piston is cast in a mold with a concentric metal ring which forms a portion of the working side wall of the piston.
  • the ferrous metal ring is first coated with a thin iron-aluminum alloy as by immersion in a suitable bath at about 1525 to about 1625 F. for a short time, as is taught in the Whitfield et a1.
  • Patents 2,396,730 and 2,455,457 are taught in the Whitfield et a1.
  • the ring is transferred to a mold and the piston is cast; the ferrous metal ring is integrally bonded to the body of aluminum or aluminum alloy forming the piston.
  • the surfaces of the piston are suitably machined, a groove being cut in the ferrous metal ring to provide a support for a piston ring.
  • the ferrous metal ring can be provided of such size as to carry several piston rings. If only one ring is provided, the groove is cut at the head end or top of the piston and is utilized to provide support for the top ring. The provision and.
  • a further object of the invention is to provide a novel mold for the casting of a piston having an integrally bonded concentric ferrous metal ring which forms a part of the side-wall working surface of the piston.
  • Figure 1 is a schematic side elevation of a mold and core, portions of the mold and core being cut away to illustrate their relation to one another in preparation for completion of the mold prior to the casting operation.
  • Figure 2 is a diagrammatic view illustrating the flow of metal in the form of mold shown in Figure 1.
  • Figure 3 is a diagrammatic View illustrating the flow of metal in another form of mold embodying the present invention.
  • Figure 4 is a sectional view illustrating the construction of one form of a machined piston produced in accordance with this invention.
  • Figure 5 is a side elevation of a piston, partially in section, as removed from the mold of this invention.
  • Figure 6 is a plan view of the piston in Figure 5.
  • this invention particularly relates to the manufacture of a piston. generally indicated at 6 and having one or more grooves 1 therein for the reception of suitable piston rings. It is preferred that at least one of these grooves, preferably the upper groove, include an integrally bonded annular ring 8 of ferrous metal in the piston side-wall working surface.
  • the aluminum or aluminum base alloy piston structure and the ferrous metal ring must be integrally bonded through a ferro-aluminum alloy. This is attained by first heating the surface of the ring to a temperature and for a time sufficient to form a ferroaluminum alloy film on the surface of the article, after which, and without cooling, the coated ring is positioned in the mold and the piston is cast. The conditions for formation of the alloy film and the general process details are disclosed in the aforementioned patents.
  • the aluminum coated ferrous metal ring is supported in such relation to the mold that it is completely embedded in the aluminum metal, as is shown in Figures 5 and 6, and excess metal must Joe removed as by machining to exhibit the ring and prior to formation of the groove 9 therein, as in Figure 4.
  • a mold generally at 2
  • a suitable core, indicated generally at 23, is placed in the mold, cover 24 being adapted to fit the top of the mold and including a riser 3
  • the mold and cover are each provided with an annular recess 26 havin a diameter larger than that of the piston proper, the recess being at an elevation in the mold corresponding to that of the position of the ferrous metal ring in the piston.
  • the recess is of a size to receive the ferrous metal ring and retain it in a spaced relation to the adjacent side wall of the completed mold.
  • the recess is discontinuous and the side wall is continued as is indicated at 21, a notchor recess 28 being provided in each such continuation 21 to provide a support for thealuminum coated ferrous metal ring.
  • At least three such supports are used to ensure centering of the ring.
  • the notches in thecoverandin the mold are preferably offset so that a minimum area of the ring is sealed against the wallon either side of the ring (see Figures and 6).
  • the ring 'is engaged with the notches 28 it will be supported in a freely spaced relation to the wall .21 :of the mold and metal can flow ,freely up-and around the ring, as has been .-indicated in * Figure 2.
  • a typical cast piston is shown in' Figures 5'and 6, with the excess metal completely surrounding the ferrous-metal ring except for those relatively small areas wherethe ring is supported in position in the mold. This excess metal is readily removed in the machining operation.
  • an improved piston structure is provided wherein theconcentric ferrous metal ring utilized as a piston ring support is adequately bonded by a ferro-aluminum bond to the piston.
  • This "same result can be achieved by providing three or more conical indentations in the surface of the ring and spaced .equally about the periphery to receive the pointed end of a pin-like support which :projectsfrbni the'mold wall, one of the three pinsb'eing spring-biased to hold the ring against the other two pins which are fixed. Because of the small area of contact between the pins, the heat loss through the pins is negligible.

Description

Dec. 9, 1952 LfsuLPRlzlo 2,620,530
MANUFACTURE OF PISTONS Filed Jun a, 1950 2 swam-41mm 1 F I r51 -El: INVEN pace/A2 521/ r/ BY 64M! 0 ATTO/Q/Yi) D 9, 1952 L. SULPRIZIO 2,620,530
MANUFACTURE OF PISTONS Filed June 8, 1950 2 SHEETS-SHEET 2 IINVENTOBU [we/m 54/ r/z/v BY I,
in) a- Patented Dec. 9, 1952 MANUFACTURE or PISTONS Lucelio Sulprizio, Castro Valley, Calif., assignor to United Engine & Machine 00., a corporation of California Application June 8, 1950, Serial No. 166,900
1 Claim. 1
This invention relates to the manufacture of pistons and the like and particularly to pistons made of aluminum or an aluminum base alloy and which are employed in engines which operate, for example, on the Otto or diesel cycle. In accordance with this invention, such a piston is cast in a mold with a concentric metal ring which forms a portion of the working side wall of the piston. The ferrous metal ring is first coated with a thin iron-aluminum alloy as by immersion in a suitable bath at about 1525 to about 1625 F. for a short time, as is taught in the Whitfield et a1. Patents 2,396,730 and 2,455,457. Immediately after the coating is applied and before the ring has cooled, the ring is transferred to a mold and the piston is cast; the ferrous metal ring is integrally bonded to the body of aluminum or aluminum alloy forming the piston. When the mass has cooled, the surfaces of the piston are suitably machined, a groove being cut in the ferrous metal ring to provide a support for a piston ring. If desired, the ferrous metal ring can be provided of such size as to carry several piston rings. If only one ring is provided, the groove is cut at the head end or top of the piston and is utilized to provide support for the top ring. The provision and. maintenance of an adequate seal about the top of the piston has long been recognized as essential to long engine life and high operating efficiency; imperfect or worn grooves and lands enable combustion gases to destroy compression factors, shorten ring life, carbonize and freeze rings with resultant cylinder wear and fuel waste. Each of these is obviated or reduced by utilizing a piston embodying and made in accordance with this invention.
It is in general the broad object of the present invention to provide a novel and improved process for the manufacture of a piston including an integrally bonded ferrous metal in the peripheral surface of the piston.
A further object of the invention is to provide a novel mold for the casting of a piston having an integrally bonded concentric ferrous metal ring which forms a part of the side-wall working surface of the piston.
The invention includes other objects and features of advantage, some of which, together with the foregoing, will appear hereinafter wherein the preferred practice of the method and the preferred form of mold embodying this invention are disclosed.
In the drawing accompanying and forming a part hereof,
Figure 1 is a schematic side elevation of a mold and core, portions of the mold and core being cut away to illustrate their relation to one another in preparation for completion of the mold prior to the casting operation.
Figure 2 is a diagrammatic view illustrating the flow of metal in the form of mold shown in Figure 1.
Figure 3 is a diagrammatic View illustrating the flow of metal in another form of mold embodying the present invention.
Figure 4 is a sectional view illustrating the construction of one form of a machined piston produced in accordance with this invention.
Figure 5 is a side elevation of a piston, partially in section, as removed from the mold of this invention.
Figure 6 is a plan view of the piston in Figure 5.
Referring to the drawings, this invention particularly relates to the manufacture of a piston. generally indicated at 6 and having one or more grooves 1 therein for the reception of suitable piston rings. It is preferred that at least one of these grooves, preferably the upper groove, include an integrally bonded annular ring 8 of ferrous metal in the piston side-wall working surface. To ensure good results, the aluminum or aluminum base alloy piston structure and the ferrous metal ring must be integrally bonded through a ferro-aluminum alloy. This is attained by first heating the surface of the ring to a temperature and for a time sufficient to form a ferroaluminum alloy film on the surface of the article, after which, and without cooling, the coated ring is positioned in the mold and the piston is cast. The conditions for formation of the alloy film and the general process details are disclosed in the aforementioned patents.
In accordance with this invention, the aluminum coated ferrous metal ring is supported in such relation to the mold that it is completely embedded in the aluminum metal, as is shown in Figures 5 and 6, and excess metal must Joe removed as by machining to exhibit the ring and prior to formation of the groove 9 therein, as in Figure 4. Thus, referring particularly to Figure 1, I have indicated a mold generally at 2| and having a cylindrical mold cavity for formation of a piston; the mold has a conventional gate 22 through which the molten metal is admitted to the :bottom of the mold. A suitable core, indicated generally at 23, is placed in the mold, cover 24 being adapted to fit the top of the mold and including a riser 3| completing the mold.
In accordance with this invention, the mold and cover are each provided with an annular recess 26 havin a diameter larger than that of the piston proper, the recess being at an elevation in the mold corresponding to that of the position of the ferrous metal ring in the piston. The recess is of a size to receive the ferrous metal ring and retain it in a spaced relation to the adjacent side wall of the completed mold. At spaced points about the annular recess 26 in each of the mold proper and the cover, the recess is discontinuous and the side wall is continued as is indicated at 21, a notchor recess 28 being provided in each such continuation 21 to provide a support for thealuminum coated ferrous metal ring. Preferably, at least three such supports are used to ensure centering of the ring. The notches in thecoverandin the mold are preferably offset so that a minimum area of the ring is sealed against the wallon either side of the ring (see Figures and 6). Thus, except at the places where the ring 'is engaged with the notches 28, it will be supported in a freely spaced relation to the wall .21 :of the mold and metal can flow ,freely up-and around the ring, as has been .-indicated in *Figure 2. Slag and oxide are thus forced into the "riser 3| and do not collect in and around the ring at its junction with-the wall, asis the case when the ring is-merely supported at-the desiredxelevation within the mold with its outer surface in engagement with the cylindrical :surface of the mold; the completepiston-after casting is shown in Figures 5 and-6 andywhen typically machined, in Figure 4.
The invention-can be practiced with a mold of the type illustrated in Figure 3 wherein-core 4| dependsiinto the mold and the ferrous-metal ring 42 is supported, as has been described, in the bottom portion'of the mold. 'The metalithen flows up and around the ring from gate 4-3, as is indicated by the arrow, the slag and oxide collecting in the upper portion of the piston about-the skirt portion where its presence is'not to undesirable.
A typical cast piston is shown in'Figures 5'and 6, with the excess metal completely surrounding the ferrous-metal ring except for those relatively small areas wherethe ring is supported in position in the mold. This excess metal is readily removed in the machining operation. In this manner, an improved piston structure is provided wherein theconcentric ferrous metal ring utilized as a piston ring support is adequately bonded by a ferro-aluminum bond to the piston. One can use any desired ferrous metal for the ring which is suited to the use of the piston.
Because of the very limited contact of the hot alloyed ring with the outer mold, the ring retains its heat and; metal flowing'overzand around it does=not=cool appreciably. This "same result can be achieved by providing three or more conical indentations in the surface of the ring and spaced .equally about the periphery to receive the pointed end of a pin-like support which :projectsfrbni the'mold wall, one of the three pinsb'eing spring-biased to hold the ring against the other two pins which are fixed. Because of the small area of contact between the pins, the heat loss through the pins is negligible.
I-claim:
In the casting of analuminum piston having an :annular iron ring supported concentrically thereon, the steps 'of coating an .iron .-ring with an iron-aluminum alloy by immersing the ring for ashort time in a molten bath-of said alloy at a bath temperature of from about l525 to about 1-625" F. and immediately thereafter supporting" the -hotring in a mold for'ithe ipiston at a plurality of spaced points about the periphery of the ring with the ri-ng;.outer wall spaced from and concentric with the -mold to provide a free-passageway for -metal how between the rmold and the ring -outer -wall, and then, while the ringisstill'hot, pouring 'a molten metal of the class consisting .of aluminumaand aluminum base alloys intothe mold to ifill the mold and embed said ring 1 therein.
LUCELIO SULPRIZIO.
REFERENCES CITED The following references are of "record in the file of this patent:
UNITED STATES PATENTS Number Name 7 Date 1,931,587 McConnel.. Oct. '24, 1933 2,052,921 'Dockrayet a1. Sept. .1, .1936 2,369,067 Mayer v ep. 19 15 2,396,730 Whitfield Mar. 19,1946
FOREIGN PATENTS I Number Country 7 Date 401,996 Germany ISept. 11.1924
US166900A 1945-02-07 1950-06-08 Manufacture of pistons Expired - Lifetime US2620530A (en)

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US576592A US2608735A (en) 1945-02-07 1945-02-07 Quick fastening device
US166900A US2620530A (en) 1945-02-07 1950-06-08 Manufacture of pistons

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2789329A (en) * 1956-02-17 1957-04-23 Sterling Aluminum Products Inc Piston molding machine
US2807435A (en) * 1951-06-12 1957-09-24 Fairchild Engine & Airplane Turbine stator blade
US2833603A (en) * 1954-06-10 1958-05-06 Joseph J Dailey Article of manufacture
US2886867A (en) * 1957-10-09 1959-05-19 Sterling Aluminum Products Inc Piston molding machine
US2978284A (en) * 1957-03-19 1961-04-04 Daub Rudolph Piston head structure
US3009237A (en) * 1954-01-25 1961-11-21 Lehmeier Carl Piston blanks
US3039744A (en) * 1955-09-01 1962-06-19 Ind Companie Heat exchangers
US3061053A (en) * 1958-08-25 1962-10-30 Kelsey Hayes Co Liquid cooled brake
US3197828A (en) * 1961-01-03 1965-08-03 Pechiney Prod Chimiques Sa Cast iron protection
US3264717A (en) * 1962-12-11 1966-08-09 Mahle Kg Process for making forged light metal pistons with ring supports
US3305918A (en) * 1963-03-19 1967-02-28 Universal American Corp Method of producing composite castforged aluminum piston with bonded ferrous ring carrier
US3380139A (en) * 1966-04-06 1968-04-30 Alum Alloy Casting Co Method of making an insert and cast piston combination
US4365399A (en) * 1978-07-12 1982-12-28 Metal Leve S.A. Industria E Comercio Manufacture of light weight pistons
US6112802A (en) * 1995-10-11 2000-09-05 Mahle Gmbh Process for producing an intermetallic join
US20150122448A1 (en) * 2012-04-27 2015-05-07 Federal-Mogul Nurnberg Gmbh Casting process and mould

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE401996C (en) * 1922-07-23 1924-09-11 Wilhelm Oehlmann Permanent mold (mold) for casting bearing shells
US1931587A (en) * 1930-07-26 1933-10-24 Metal Castings Ltd Casting metals in metal molds or dies
US2052921A (en) * 1935-01-02 1936-09-01 Charles J Dockray Chilled metal mold casting
US2369067A (en) * 1939-11-25 1945-02-06 Mayer Ernest Mold
US2396730A (en) * 1941-10-24 1946-03-19 Al Fin Corp Coating metal

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE401996C (en) * 1922-07-23 1924-09-11 Wilhelm Oehlmann Permanent mold (mold) for casting bearing shells
US1931587A (en) * 1930-07-26 1933-10-24 Metal Castings Ltd Casting metals in metal molds or dies
US2052921A (en) * 1935-01-02 1936-09-01 Charles J Dockray Chilled metal mold casting
US2369067A (en) * 1939-11-25 1945-02-06 Mayer Ernest Mold
US2396730A (en) * 1941-10-24 1946-03-19 Al Fin Corp Coating metal

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2807435A (en) * 1951-06-12 1957-09-24 Fairchild Engine & Airplane Turbine stator blade
US3009237A (en) * 1954-01-25 1961-11-21 Lehmeier Carl Piston blanks
US2833603A (en) * 1954-06-10 1958-05-06 Joseph J Dailey Article of manufacture
US3039744A (en) * 1955-09-01 1962-06-19 Ind Companie Heat exchangers
US2789329A (en) * 1956-02-17 1957-04-23 Sterling Aluminum Products Inc Piston molding machine
US2978284A (en) * 1957-03-19 1961-04-04 Daub Rudolph Piston head structure
US2886867A (en) * 1957-10-09 1959-05-19 Sterling Aluminum Products Inc Piston molding machine
US3061053A (en) * 1958-08-25 1962-10-30 Kelsey Hayes Co Liquid cooled brake
US3197828A (en) * 1961-01-03 1965-08-03 Pechiney Prod Chimiques Sa Cast iron protection
US3264717A (en) * 1962-12-11 1966-08-09 Mahle Kg Process for making forged light metal pistons with ring supports
US3305918A (en) * 1963-03-19 1967-02-28 Universal American Corp Method of producing composite castforged aluminum piston with bonded ferrous ring carrier
US3380139A (en) * 1966-04-06 1968-04-30 Alum Alloy Casting Co Method of making an insert and cast piston combination
US4365399A (en) * 1978-07-12 1982-12-28 Metal Leve S.A. Industria E Comercio Manufacture of light weight pistons
US6112802A (en) * 1995-10-11 2000-09-05 Mahle Gmbh Process for producing an intermetallic join
US20150122448A1 (en) * 2012-04-27 2015-05-07 Federal-Mogul Nurnberg Gmbh Casting process and mould

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