WO2017068059A1 - Piston multiply joined by means of a combined hybrid welding method - Google Patents

Piston multiply joined by means of a combined hybrid welding method Download PDF

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Publication number
WO2017068059A1
WO2017068059A1 PCT/EP2016/075260 EP2016075260W WO2017068059A1 WO 2017068059 A1 WO2017068059 A1 WO 2017068059A1 EP 2016075260 W EP2016075260 W EP 2016075260W WO 2017068059 A1 WO2017068059 A1 WO 2017068059A1
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WO
WIPO (PCT)
Prior art keywords
joining
piston
parts
welding method
zones
Prior art date
Application number
PCT/EP2016/075260
Other languages
German (de)
French (fr)
Inventor
Steffen Stork
Original Assignee
Ks Kolbenschmidt Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ks Kolbenschmidt Gmbh filed Critical Ks Kolbenschmidt Gmbh
Publication of WO2017068059A1 publication Critical patent/WO2017068059A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/24Preliminary treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/10Making specific metal objects by operations not covered by a single other subclass or a group in this subclass pistons
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/003Pistons
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00Pistons 
    • F02F3/0015Multi-part pistons
    • F02F3/003Multi-part pistons the parts being connected by casting, brazing, welding or clamping
    • F02F2003/0061Multi-part pistons the parts being connected by casting, brazing, welding or clamping by welding

Definitions

  • the invention relates to a method for producing a piston, wherein an upper part having at least one joining zone and a lower part having at least one joining zone are manufactured separately from one another and then joined together inseparably with each other in the region of the joining zones by means of a joining method.
  • the invention is therefore based on the object to provide a method for producing a piston, with which the above-described disadvantages are avoided.
  • At least one of the joining zones of the upper part and / or of the lower part is heated to melting by a resistance welding process and then the two parts are rotated relative to one another and axially compressed.
  • the production of upper and lower parts separately can be done in a conventional manner by forging, casting or the like. The same applies to the choice of material, so that upper part and lower part may consist of the same materials or different materials.
  • the upper part and / or the lower part are heated by resistance welding.
  • the joining zone of the upper part and / or the joining zone of the lower part is purposefully heated until it melts, preparing it for the next processing step.
  • the next processing step is to either rotate the two parts and then compress them by applying an axial force (along the piston stroke axis).
  • an axial force (along the piston stroke axis).
  • both the application of the axial force to compress the insert both parts and the rotational movement almost simultaneously or temporally spaced from each other.
  • the inventive method for producing a piston has the advantage that the molten surface of the affected joining zone is torn apart by the rotational movement of the two parts to each other, so that thereby an optimal non-detachable connection of the two parts takes place together. It can thus no more local break points arise.
  • the method according to the invention has the significant advantage that, to delimit the known process also known as "spinduction", the energy is introduced into the joining zones by the much lower energy resistance welding method, which means that when the joining zones melt by means of induction heat, the energy input is about 95% due to induction heat takes place, while according to the invention, the energy is introduced by resistance welding, resulting in a significant energy savings.In addition to this energy saving and no costly high-frequency generator is necessary.
  • the upper part and / or the lower part is used as an anode for the resistance welding process.
  • no additional tool such as the high-frequency generator for generating the induction heat
  • at least a part of the piston serves as a tool.
  • the costs can be significantly reduced, especially in the mass production of pistons.
  • the upper part is fixed and the lower part is set in rotation or vice versa.
  • the manufacturing process can be optimized in which one part of the piston is clamped in one tool (and in particular simultaneously serves as anode), while the other part is set in rotation.
  • both parts are moved towards each other, that the fixed part is not moved and the rotating part is moved to the fixed part or that the rotating part remains in a plane, wherein the fixed part of the in the fixed plane rotating part is pressed.
  • the piston blank consisting of the undissolvably joined to the upper part lower part, finished to a ready piston.
  • the upper part comprises a ring field, optionally, for example, a cooling channel and / or a combustion bowl and possibly further elements of the piston.
  • the lower part likewise comprises elements such as a piston shaft (or supporting diametrically opposite shaft wall sections), bolt bores, pin bosses, possibly connecting walls and the like, in a manner known per se.
  • the joining zones of the upper part and of the lower part are formed, for example, by mutually facing circumferential webs, wherein more than one common joining region (eg two concentrically mutually juxtaposed joining regions) may also be present.
  • more than one common joining region eg two concentrically mutually juxtaposed joining regions
  • this is just an example, so it on the design of at least one joining zone of the upper part and the lower part does not arrive.

Abstract

The invention relates to a method for producing a piston, wherein an upper part having at least one joining zone and a lower part having at least one joining zone are produced separately from each other and thereafter are permanently joined to each other in the region of the joining zones by means of a joining method, characterized in that at least one of the joining zones of the upper part and/or of the lower part is heated to the point of melting by means of a resistance welding method and thereafter the two parts are set in rotation in relation to each other and are axially pressed together.

Description

Mehrfach gefügter Kolben mittels kombiniertem Hybridschweißverfahren  Multiple jointed piston using combined hybrid welding process
B E S C H R E I B U N G DESCRIPTION
Die Erfindung betrifft ein Verfahren zur Herstellung eines Kolbens, wobei ein zumindest eine Fügezone aufweisendes Oberteil und ein zumindest eine Fügezone aufweisendes Unterteil separat voneinander gefertigt und danach unlösbar miteinander im Bereich der Fügezonen mittels eines Fügeverfahrens zusammengefügt werden, gemäß den Merkmalen des Oberbegriffes des Patentanspruches 1 . The invention relates to a method for producing a piston, wherein an upper part having at least one joining zone and a lower part having at least one joining zone are manufactured separately from one another and then joined together inseparably with each other in the region of the joining zones by means of a joining method.
Aus der WO 2005/060315 ist es bekannt, zwei Teile (Oberteil und Unterteil) eines Kolbens zunächst separat voneinander herzustellen. Diese beiden Teile werden mittels eines Induktionsringes im Bereich ihrer einander zuweisenden Fügezonen aufgeschmolzen und danach die beiden Teile unter Aufbringung einer axialen Kraft zusammengerückt, sodass die beiden Teile im Bereich ihrer aufgeschmolzenen und einander zuweisenden Fügezonen miteinander zusammengefügt werden, wobei eine unlösbare Verbindung dieser beiden Teile zueinander nach dem Erkalten des Fügebereiches erfolgt. From WO 2005/060315 it is known to initially produce two parts (upper part and lower part) of a piston separately from one another. These two parts are melted by means of an induction ring in the region of their facing joining zones and then the two parts brought together under application of an axial force, so that the two parts are joined together in the region of their molten and facing joining zones together, with an indissoluble connection of these two parts to each other after the cooling of the joining area.
Obwohl ein solches Verfahren zufriedenstellend funktioniert, ist aufgrund des Einbringens der Induktionswärme, die zum Aufschmelzen der Fügezonen erforderlich ist, eine sehr große Energiemenge erforderlich. Außerdem ist das Zusammenbringen von Oberteil und Unterteil durch eine axiale Bewegung (entlang der Kolbenhubachse) aufeinander zu mit der Gefahr verbunden, dass die aufgeschmolzene Fügezone in ihrer Oberfläche nach dem Induktionserwärmen schon geringfügig erkaltet und zumindest bereichsweise eine Haut bildet, die einer optimalen Fügeverbindung entgegensteht. Daher besteht die Gefahr von lokalen Bereichen, die nicht unlösbar miteinander verbunden sind und somit während des Betriebes des Kolbens in dem Zylinder der Brennkraftmaschine Sollbruchstellen darstellen. Although such a method works satisfactorily, a very large amount of energy is required due to the introduction of the induction heat required to melt the joining zones. In addition, the bringing together of upper part and lower part by an axial movement (along the piston stroke axis) to each other with the risk that the molten joining zone already slightly cooled in its surface after the induction heating and at least partially forms a skin that precludes an optimal joining connection. Therefore, there is a danger of local areas that are not inextricably linked and thus during the Operation of the piston in the cylinder of the internal combustion engine represent predetermined breaking points.
Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Kolbens bereitzustellen, mit dem die eingangs geschilderten Nachteile vermieden werden. The invention is therefore based on the object to provide a method for producing a piston, with which the above-described disadvantages are avoided.
Diese Aufgabe ist durch die Merkmale des Patentanspruches 1 gelöst. Erfindungsgemäß ist vorgesehen, dass zumindest eine der Fügezonen des Oberteiles und/oder des Unterteiles durch ein Widerstandsschweißverfahren bis zur Aufschmelzung erwärmt werden und danach die beiden Teile zueinander in Rotation versetzt und axial zusammengedrückt werden. Zunächst erfolgt die Herstellung von Oberteil und Unterteil separat voneinander. Dies kann in an sich bekannter Weise durch Schmieden, Gießen oder dergleichen erfolgen. Gleiches betrifft die Materialwahl, sodass Oberteil und Unterteil aus gleichen Materialien oder voneinander unterschiedlichen Materialien bestehen können. This object is solved by the features of claim 1. According to the invention, at least one of the joining zones of the upper part and / or of the lower part is heated to melting by a resistance welding process and then the two parts are rotated relative to one another and axially compressed. First, the production of upper and lower parts separately. This can be done in a conventional manner by forging, casting or the like. The same applies to the choice of material, so that upper part and lower part may consist of the same materials or different materials.
Nachdem diese beiden Teile separat voneinander unter Ausbildung von korrespondierenden Fügezonen hergestellt worden sind, erfolgt eine Aufheizung des Oberteiles und/oder des Unterteiles durch Widerstandsschweißen. Durch diesen Prozess wird gezielt die Fügezone des Oberteiles und/oder die Fügezone des Unterteiles bis zur Aufschmelzung erwärmt, wodurch sie für den nächsten Verarbeitungsschritt vorbereitet sind. After these two parts have been produced separately from one another with the formation of corresponding joining zones, the upper part and / or the lower part are heated by resistance welding. By means of this process, the joining zone of the upper part and / or the joining zone of the lower part is purposefully heated until it melts, preparing it for the next processing step.
Der nächste Verarbeitungsschritt ist darin zu sehen, dass entweder die beiden Teile in Rotation versetzt werden und danach durch Aufbringung einer axialen Kraft (entlang der Kolbenhubachse) zusammengedrückt werden. Alternativ dazu ist es möglich, zunächst die axiale Kraft aufzubringen und die beiden Teile axial zusammenzudrücken, wobei die Rotation erst danach einsetzt. Schließlich ist es denkbar, dass sowohl das Aufbringen der axialen Kraft zum Zusammendrücken der beiden Teile und die Rotationsbewegung nahezu gleichzeitig oder zeitlich kurz voneinander beabstandet einsetzen. The next processing step is to either rotate the two parts and then compress them by applying an axial force (along the piston stroke axis). Alternatively, it is possible to first apply the axial force and compress the two parts axially, wherein the rotation starts only afterwards. Finally, it is conceivable that both the application of the axial force to compress the insert both parts and the rotational movement almost simultaneously or temporally spaced from each other.
Durch den axialen Pressvorgang und die Rotation wird die aufgeschmolzene Oberfläche der Fügezonen aufgerissen und es entsteht eine stoffschlüssige Verbindung zunächst durch das Widerstandsschweißverfahren und danach durch das Reibschweißverfahren (Rotation und Zusammendrücken). Due to the axial pressing process and the rotation, the melted surface of the joining zones is torn open and a cohesive connection is formed first by the resistance welding process and then by the friction welding process (rotation and compression).
Während bisher davon ausgegangen wurde, dass zunächst die Fügezonen durch ein Widerstandschweißverfahren bis zur Aufschmelzung erwärmt werden und nach erfolgter Aufschmelzung das Reibschweißverfahren eingesetzt wird, ist es auch denkbar, schon während der Aufschmelzung der Fügezonen (d.h. während der Durchführung des Widerstandschweißverfahrens) das Reibschweißverfahren zu beginnen. While it has hitherto been assumed that first the joining zones are heated to melting by a resistance welding method and the friction welding method is used after melting, it is also conceivable to start the friction welding method already during the melting of the joining zones (ie during the execution of the resistance welding method) ,
Das erfindungsgemäße Verfahren zur Herstellung eines Kolbens hat den Vorteil, dass durch die Rotationsbewegung der beiden Teile zueinander die aufgeschmolzene Oberfläche der betroffenen Fügezone aufgerissen wird, sodass dadurch eine optimale unlösbare Verbindung der beiden Teile miteinander erfolgt. Es können somit keine lokalen Sollbruchstellen mehr entstehen. Außerdem hat das erfindungsgemäße Verfahren den wesentlichen Vorteil, dass zur Abgrenzung des bekannten auch„Spinduction" genannten Prozesses die Energieeinbringung in die Fügezonen durch das wesentlich energieärmere Widerstandschweißverfahren erfolgt. Das bedeutet, dass beim Aufschmelzen der Fügezonen mittels Induktionswärme die Energieeinbringung zu etwa 95% durch Induktionswärme erfolgt, während nach der Erfindung die Energie durch Widerstandschweißen eingebracht wird, was zu einer deutlichen Energieeinsparung führt. Neben dieser Energieeinsparung ist auch kein kostenintensiver Hochfrequenz-Generator notwendig. The inventive method for producing a piston has the advantage that the molten surface of the affected joining zone is torn apart by the rotational movement of the two parts to each other, so that thereby an optimal non-detachable connection of the two parts takes place together. It can thus no more local break points arise. In addition, the method according to the invention has the significant advantage that, to delimit the known process also known as "spinduction", the energy is introduced into the joining zones by the much lower energy resistance welding method, which means that when the joining zones melt by means of induction heat, the energy input is about 95% due to induction heat takes place, while according to the invention, the energy is introduced by resistance welding, resulting in a significant energy savings.In addition to this energy saving and no costly high-frequency generator is necessary.
In Weiterbildung der Erfindung wird das Oberteil und/oder das Unterteil als Anode für das Widerstandschweißverfahren eingesetzt. Das bedeutet, dass kein zusätzliches Werkzeug (wie z.B. der Hochfrequenz-Generator zur Erzeugung der Induktionswärme) erforderlich ist, sondern dass das zumindest eine Teil des Kolbens (Oberteil und/oder Unterteil) als Werkzeug dient. Hierdurch lassen sich insbesondere bei der Serienproduktion von Kolben deutlich die Kosten senken. In a further development of the invention, the upper part and / or the lower part is used as an anode for the resistance welding process. This means that no additional tool (such as the high-frequency generator for generating the induction heat) is required, but that at least a part of the piston (Top and / or lower part) serves as a tool. As a result, the costs can be significantly reduced, especially in the mass production of pistons.
In Weiterbildung der Erfindung steht das Oberteil fest und das Unterteil wird in Rotation versetzt oder umgekehrt. Dadurch lässt sich der Herstellprozess optimieren, in dem das eine Teil des Kolbens in ein Werkzeug eingespannt wird (und insbesondere gleichzeitig als Anode dient), während das andere Teil in Rotation versetzt wird. Hierbei ist es für das Zusammendrücken denkbar, dass beide Teile aufeinander zubewegt werden, dass das feststehende Teil nicht bewegt wird und das rotierende Teil auf das feststehende Teil bewegt wird oder dass das rotierende Teil in einer Ebene verbleibt, wobei das feststehende Teil auf das in der feststehenden Ebene rotierende Teil gedrückt wird. In a further development of the invention, the upper part is fixed and the lower part is set in rotation or vice versa. As a result, the manufacturing process can be optimized in which one part of the piston is clamped in one tool (and in particular simultaneously serves as anode), while the other part is set in rotation. Here it is conceivable for the compression that both parts are moved towards each other, that the fixed part is not moved and the rotating part is moved to the fixed part or that the rotating part remains in a plane, wherein the fixed part of the in the fixed plane rotating part is pressed.
In Weiterbildung der Erfindung wird der Kolbenrohling, bestehend aus den mit dem Oberteil unlösbar gefügten Unterteil, zu einem betriebsbereiten Kolben fertigbearbeitet. Nachdem die beiden separat voneinander hergestellten Teile mit dem Verfahren nach der Erfindung unlösbar zusammengefügt worden sind, ist es von Vorteil, dass dieses Verfahren keine deutlichen Reibschweißwülste erzeugt, sondern lediglich eine umlaufende erhabene Stelle. Je nach Lage der Fügezonen ist es denkbar, die entstehenden minimalen Wülste entweder zu belassen (wenn sie beim Betrieb des Kolbens nicht stören) oder aber zu entfernen (insbesondere dann, wenn die Fügezonen nahe am Außenumfang des Kolbens angeordnet sind). In a further development of the invention, the piston blank, consisting of the undissolvably joined to the upper part lower part, finished to a ready piston. After the two separately produced parts have been joined together inextricably by the method according to the invention, it is advantageous that this method produces no significant Reibschweißwülste, but only a circumferential raised location. Depending on the position of the joining zones, it is conceivable either to leave the resulting minimum beads (if they do not interfere with the operation of the piston) or to remove them (in particular if the joining zones are arranged close to the outer circumference of the piston).
In an sich bekannter Weise umfasst das Oberteil ein Ringfeld, optional beispielsweise einen Kühlkanal und/oder eine Brennraummulde und ggf. weitere Elemente des Kolbens. Das Unterteil umfasst ebenfalls in an sich bekannter Weise Elemente wie Kolbenschaft (oder tragende diametral gegenüberliegende Schaftwandabschnitte), Bolzenbohrungen, Bolzennaben, ggf. Verbindungswände und dergleichen. In known manner, the upper part comprises a ring field, optionally, for example, a cooling channel and / or a combustion bowl and possibly further elements of the piston. The lower part likewise comprises elements such as a piston shaft (or supporting diametrically opposite shaft wall sections), bolt bores, pin bosses, possibly connecting walls and the like, in a manner known per se.
Die Fügezonen des Oberteiles und des Unterteiles werden beispielsweise durch aufeinander zuweisende umlaufende Stege gebildet, wobei auch mehr als ein gemeinsamer Fügebereich (z.B. zwei konzentrisch ineinander liegende Fügebereiche) vorhanden sein können. Dies ist jedoch nur beispielhaft, sodass es auf die Ausgestaltung der zumindest einen Fügezone des Oberteiles und des Unterteiles nicht ankommt. The joining zones of the upper part and of the lower part are formed, for example, by mutually facing circumferential webs, wherein more than one common joining region (eg two concentrically mutually juxtaposed joining regions) may also be present. However, this is just an example, so it on the design of at least one joining zone of the upper part and the lower part does not arrive.

Claims

P A T E N T A N S P R Ü C H E PATENT APPLICATIONS
1 . Verfahren zur Herstellung eines Kolben, wobei ein zumindest eine Fügezone aufweisendes Oberteil und ein zumindest eine Fügezone aufweisendes Unterteil separat voneinander gefertigt und danach unlösbar miteinander im Bereich der Fügezonen mittels eines Fügeverfahrens zusammengefügt werden, dadurch gekennzeichnet, dass zumindest eine der Fügezonen des Oberteiles und/oder des Unterteiles durch ein Widerstandsschweißverfahren bis zur Aufschmelzung erwärmt werden und danach die beiden Teile zueinander in Rotation versetzt und axial zusammengedrückt werden. 1 . A method for producing a piston, wherein an upper part having at least one joining zone and a lower part having at least one joining zone are manufactured separately from each other and then joined inseparably together in the region of the joining zones by means of a joining process, characterized in that at least one of the joining zones of the upper part and / or of the lower part are heated by a resistance welding process to the melting and then the two parts are mutually rotated and axially compressed.
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass das Oberteil und/oder das Unterteil als Anode für das Widerstandsschweißverfahren eingesetzt wird. 2. The method according to claim 1, characterized in that the upper part and / or the lower part is used as the anode for the resistance welding process.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das3. The method according to claim 1 or 2, characterized in that the
Oberteil feststeht und das Unterteil in Rotation versetzt wird oder umgekehrt. Upper part is fixed and the lower part is set in rotation or vice versa.
4. Verfahren nach Anspruch 1 , 2 oder 3, dadurch gekennzeichnet, dass der4. The method according to claim 1, 2 or 3, characterized in that the
Kolbenrohling, bestehend aus dem mit dem Oberteil unlösbar gefügten Unterteil, zu einem betriebsbereiten Kolben fertig bearbeitet wird. Piston blank, consisting of the undissolvably joined to the upper part lower part, is finished to a ready-piston operation.
PCT/EP2016/075260 2015-10-21 2016-10-20 Piston multiply joined by means of a combined hybrid welding method WO2017068059A1 (en)

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Application Number Priority Date Filing Date Title
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DE102015220520 2015-10-21

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1277579A (en) * 1968-07-15 1972-06-14 Wellworthy Ltd Pistons
WO2004044409A2 (en) * 2002-11-06 2004-05-27 Federal-Mogul Corporation Piston and method of manufacture
WO2005060315A1 (en) 2003-12-12 2005-06-30 Federal-Mogul Corporation Piston and method of manufacture
DE102010033879A1 (en) * 2010-08-10 2012-02-16 Mahle International Gmbh Method for producing a piston for an internal combustion engine and pistons for an internal combustion engine

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1277579A (en) * 1968-07-15 1972-06-14 Wellworthy Ltd Pistons
WO2004044409A2 (en) * 2002-11-06 2004-05-27 Federal-Mogul Corporation Piston and method of manufacture
WO2005060315A1 (en) 2003-12-12 2005-06-30 Federal-Mogul Corporation Piston and method of manufacture
DE102010033879A1 (en) * 2010-08-10 2012-02-16 Mahle International Gmbh Method for producing a piston for an internal combustion engine and pistons for an internal combustion engine

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