Techniques for Manufacturing and Coating Liners of Small Engines

Currently there are three different types of bore solutions for small engines. 1) High silicon aluminum running with cast iron piston rings and a coated piston 2) Cast iron liner fitted to an aluminum block or cylinder 3) Nickel composite coating on an aluminum liner, cylinder, or block.

A new method and apparatus has been developed to reduce the manufacturing tasks and costs of a bore solution. This method serves to produce a finished liner that can be installed into a block or cylinder, with less energy and fewer steps. This new method involves turning a liner from aluminum and coating with nickel-silicon carbide. For the finish honing, an apparatus was developed that enables a liner to be honed for interference or clearance bonded fit into the block or the cylinder.

This paper is divided into two parts. The first part addresses the manufacturing and installation of liners and the second part gives engine designers some specifics of nickel ceramic composite electrolytic coatings.