Federal Mogul Corporation

Port Huron, MI, United States

Federal Mogul Corporation

Port Huron, MI, United States
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Patent
Federal Mogul Corporation | Date: 2016-11-15

A steel piston achieving increased thermal brake efficiency in an internal combustion engine is provided. The piston includes a crown presenting a combustion surface, an outer side wall depending from the combustion surface, an outer cooling gallery, and an undercrown cooling gallery. The outer cooling gallery extends circumferentially along the outer side wall beneath the combustion surface. According to one embodiment, the outer cooling gallery is sealed and filled with air, argon, helium, xenon, or carbon dioxide as a cooling media. In this embodiment, the undercrown cooling gallery is filled with air as a cooling media and includes an open inlet hole having a diameter being from 2% to 4% of an outer diameter of the piston. Alternatively, the undercrown cooling gallery is filled with air, argon, helium, xenon, or carbon dioxide as a cooling media, and the inlet hole is sealed.


Patent
Federal Mogul Corporation | Date: 2017-01-26

A method of manufacturing a spark plug (20) for being threaded into a cylinder head (28) of an internal combustion engine is provided. The spark plug (20) includes a shell (24) with threads (26) disposed at a predetermined rotational position (a) relative to a shell outer surface (64) and ground electrode (34). The position of the threads (26) relative to the ground electrode (34) places the ground electrode (34) in a desired position in the combustion chamber (22) and relative to components of the engine, thus allowing the ground electrode (34) to provide a robust and reliable ignition. When multiple spark plugs (20) are formed, the threads (26) in each of the shells (24) are repeatedly and accurately formed at the predetermined rotational position (a) by locating the ground electrode (34), threads (26), and dies (76) of a thread forming apparatus (102) in specific locations.


Patent
Federal Mogul Corporation | Date: 2017-01-23

A piston with a cooling gallery containing an open cell radiator is provided. The radiator has a large thermally conductive surface area that acts as a heat-sink to remove heat from the piston. Heat from the piston is transmitted from the radiator to cooling oil that enters the cooling gallery via an oil inlet formed in a floor of the cooling gallery and exits the cooling gallery via an oil outlet. The piston comprises a piston body including an upper part presenting an upper combustion surface and an undercrown surface. A ring belt depends from the upper combustion surface, and the cooling gallery extends around the piston body beneath the undercrown surface radially inwardly of the ring belt. The radiator includes a plurality of fins extending annularly around the cooling gallery. The fins of the radiator are spaced from one another by gaps extending annularly around the cooling gallery.


Patent
Federal Mogul Corporation | Date: 2017-07-05

A hybrid induction welded piston including an upper piston part welded to a lower piston part is provided. The piston is produced by induction heating the upper piston part and the lower piston part, and bringing the parts together to a part growth compensated position. The method then includes rotating the upper piston part 17 to 34 degrees clockwise and then 17 to 34 degrees counterclockwise. In addition to controlling the axial position and degree of rotation, the force applied to the piston parts is controlled so that preferably no flash is formed in a narrow cooling chamber of the piston. During the rotating steps, the pressure gradually increases to a maximum level which occurs while the upper piston part is rotating in the second direction. The piston includes a homogeneous metallurgical bond across the weld and no indentation on the outer surface at the weld prior to machining.


Patent
Federal Mogul Corporation | Date: 2017-04-26

A multilayer gasket for establishing a gas and/or fluid-tight seal between a cylinder head and engine block of an internal combustion engine is provided. The gasket includes a pair of functional layers each presenting a full bead and a half bead. A single-piece stopper with a fold over adjacent the combustion chamber opening is disposed between the function layers. The stopper extends between a fifth edge and a sixth edge, wherein the sixth edge is disposed radially between the full beads and the half beads. The stopper can be cranked or coined in a location disposed between the fold over and the full beads, The stopper can also include a secondary fold over adjacent the sixth edge. A distance layer is optionally disposed between the stopper and one of the functional layers. The distance layer can also he cranked or coined between the fold over and the full beads.


A piston capable of withstanding high temperatures and extreme conditions of a combustion chamber of an internal combustion engine and manufactured with reduced costs is provided. The method of manufacturing the piston includes casting or forging the bulk of the piston as a single-piece with an open cooling gallery from an economical first material, such as steel, cast iron, or aluminum. The method further includes forming a portion of a combustion bowl surface, which is a small area of the piston directly exposed to the combustion chamber, from a second material by additive machining. The second material has a higher thermal conductivity and higher resistance to oxidation, erosion, and oil coking, compared to the first material. The additive machining process is efficient and creates little waste, which further reduces production costs.


Patent
Federal Mogul Corporation | Date: 2017-03-08

A steel piston for an internal combustion including a cooling gallery containing a solid coolant, such as an aluminum-based material, is provided. The solid coolant has a thermal conductivity which is greater than the thermal conductivity of the steel material and fills at least 15 volume percent (vol. %) of the cooling gallery. The solid coolant provides for exceptional cooling along a crown of the piston, reduces corrosion and erosion along the crown, and avoids the problem of oil coking.


A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidize during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.


Patent
Federal Mogul Corporation | Date: 2017-01-23

A sliding element, such as a piston ring, including a substrate, base coating, and relatively thin sliding coating is provided. The base coating is typically applied to a running surface of the substrate by PVD, CVD, galvanic deposition, electrodeposition, or a thermal spray process. The sliding coating includes a polymer matrix and hard particles disposed throughout the matrix. The sliding coating is applied to the base coating when the base coating is still in its as-applied condition and has a surface roughness of at least 4.0 m. During use of the sliding element, the thin sliding coating acts as a sacrificial run-in layer. In addition, as the polymer matrix of the sliding coating wears away, the hard particles polish the rough surface of the base coating. Thus, polishing or lapping of the as-applied base coating prior to use of the sliding element is not required.


A piston for a high temperature internal combustion engine is provided. The piston includes an upper wall, base wall, outer rib, and inner rib defining a cooling chamber therebetween, and a plurality of ring grooves formed in the outer rib. Only the second ring groove is formed with the keystone cross-section, and all of the other ring grooves are formed with the conventional rectangular cross-section. Thus, the piston can be formed with low manufacturing costs and can also provide exceptional performance when used in high temperature combustion engines, wherein the temperature at the first ring groove is greater than 280s C, and thus prevents carbon from depositing or bums off any carbon deposits, but the temperature at the second ring groove is between 200 C and 280 C, in which case carbon deposits can form and cause the piston ring to stick.

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