# Patent

## Title
Repaired engine block and repair method

## Abstract

A block for an internal combustion engine having at least one coated cylinder bore, which has a chamfer at a sealing surface with respect to a cylinder head, wherein the chamfer is a curved chamfer.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to DE 10 2012 201 483.7, filed Feb. 2, 2012, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The invention relates to a block for an internal combustion engine having a coated cylinder bore, which has a chamfer at a sealing surface with respect to a cylinder head.
BACKGROUND
It is known to repair worn cylinder bores of engine blocks. If the block is composed exclusively of gray cast iron, the cylinder bore can be bored out, re-coated by thermal spraying and then finish-machined to the original dimensions.
However, if the block is composed of aluminum (or a material having similar mechanical properties), such a repair may not be readily possible. But the piston does not always run directly in the engine block material because this material may not meet higher tribological requirements and the replacement of the piston and cylinder as principal wearing components is also considerably more complex. For this reason, a cylinder liner made of a more wear resistant material is often installed in the cylinder bore of an aluminum block. In a repair, the inner surface of the liner is re-bored and superfinished by honing. Cast-iron or aluminum alloys (usually with silicon) have proven suitable as materials for cylinder liners.
Although re-coating as above is possible, there is often flaking etc. of the new material, owing, for example, to the over-spraying of the block material with the different liner material and the differing thermal properties thereof. Finish-machining of the top surface or sealing surface with respect to the cylinder head may therefore be necessary.
DE 10 2009 008 741 A1 discloses a block for an internal combustion engine having at a cylinder bore which has a double chamfer at a sealing surface with respect to a cylinder head. The double chamfer consists of first and second chamfers inclined at two different angles with respect to the cylinder bore axis. The machining of such a double chamfer is complex and expensive, as is the milling cutter used to create such a double chamfer.
SUMMARY
In an embodiment disclosed herein, an engine block is formed of a first material and defines a cylinder bore terminating at a sealing surface. The block comprises a bore liner within the cylinder bore and formed of a second material. An end of the liner is spaced from the sealing surface to leave an annular surface of the first material exposed adjacent the sealing surface. A curved chamfer is formed at a sealing surface end of the bore and extends into the annular surface and the end of the liner.
By virtue of the fact that the chamfer is a curved, single chamfer, it is possible to produce the cylinder bore chamfer in one machining operation by means of a simple tool and, at the same time, to achieve an advantageous transition between materials. An appropriately designed milling cutter, drill or boring tool can be used as a tool.
In another embodiment, a method of repairing a worn liner in an engine block cylinder bore comprises machining the liner to form an inlet surface of increased diameter, the inlet terminating a distance from a sealing surface end of the bore. A repair coating is then sprayed onto the inlet surface, and the coating is machined to a nominal bore diameter. A curved chamfer is then formed at the sealing surface end of the bore and extends into the bore to the liner.
In this method, all the sprayed material is removed from the base material between the sealing surface and the cylinder liner. This is advantageous because the sprayed material may not adhere as well to the base material as to the material of the cylinder liner. Due to instances of ovality in the cylinder bore, it may also be worthwhile for the chamfer to extend partially into the cylinder liner itself to ensure that the sprayed material is entirely removed from the base material. The curved chamfer advantageously allows the removal of the sprayed material without removing a large amount of base material from the block itself.
The curved chamfer prevents flaking of the material of the spray-on layer at the transition between the different materials of the block and of the liner, thus making it possible to repair even blocks made of aluminum or other alloys.
In particular, it may be advantageous if the chamfer forms a trumpet-shaped extension of the cylinder bore toward the sealing surface in the axial direction of the cylinder bore.
It has proven particularly advantageous here if, in the axial direction of the cylinder bore, the chamfer has a radius which is about 0.1 mm larger at the sealing surface than the original cylinder bore radius and, if appropriate, the chamfer extends from the sealing surface into the cylinder bore to a depth of from 2 to 6 mm, in particular 3.5 mm. In this case, the chamfer should have a radius of about 40 mm to 100 mm.



BRIEF DESCRIPTION OF THE DRAWINGS
Further details, features and advantages of the invention will emerge from the following description of an illustrative embodiment with reference to the drawing, in which
FIG. 1 shows a longitudinal section through a web between two cylinder bores of an engine block; and
FIG. 2 shows an enlarged detail of FIG. 1 in the region of the chamfer.



DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
The figures show sections through an engine block 1 in the region of a web 2, which separates two cylinder bores 3. Here, FIG. 1 shows an overview and FIG. 2 shows the enlarged detail A from FIG. 1.
In the cylinder bores 3, the cylinder liners 4 are cast into the block 1. The cylinder liners 4 may typically be composed of steel or gray cast iron, while the base material of the block 1 may typically consist of an aluminum alloy. A sealing surface 5 with respect to a cylinder head (not shown) forms the top end of the block 1. The cylinder liners 4 do not extend to reach the sealing surface 5 but rather stop short of the surface, with the result that annular flanges 6 composed of the block material are present between the sealing surface 5 and the ends of the cylinder liners 4. Flanges 6 have a longitudinal or axial dimension indicated as D in the figures.
The block 1 shown requires repairing, such as may be necessary if the cylinder liners 4 become worn due to excessive stress. The repairing is accomplished by means of a spray repair method. To prepare the block for the spray-on repair material, the cylinder liners 4 are bored out from below (the ends of the bores that open to the crankcase, not shown) in at least the region of the worn piston bearing surfaces, thereby giving rise to a relieved portion or inlet 7 having radius B1 as indicated in FIG. 2. The un-bored projecting section 8 of the cylinder liner 4 between the annular flange 6 and the inlet 7 retains the original, smaller bore radius, indicated as B2.
The two cylinder bores 3 are shown at different stages of the repair process. The left-hand cylinder bore 3 is shown in a state immediately after the application of a spray-on layer 9. Layer 9 may be applied by any suitable metal spraying method, e.g. plasma powder spraying, plasma transferred wire arc spraying, etc. The spray-on layer 9 is applied to a thickness greater than is desired in the finished (repair-complete) state and extends beyond the inlet 7 onto the circumferential surfaces of the projecting section 8 and onto the annular flange 6. For this reason, the spray-on layer 9 must be removed to achieve the nominal dimension of the cylinder bore 3 in a further working step.
The right-hand cylinder bore 3 shows the state after the machining of the block 1 and, in particular, of the spray-on layer 9. In the region of the inlet 7, the spray-on layer 9 has been machined down to the nominal bore dimension, for example by a honing operation. The surface finish after honing is indicated by the crisscross score marks at 10.
In the region of the annular flange 6, the machining may be made more difficult by the fact that the spray-on layer 9 typically does not adhere well to the base material of the block 1. Another potential problem may be caused by any pre-existing chamfering 11 present on the block 1 as originally produced, which may have been intended to facilitate the installation of the piston into the cylinder bore. By means of the curved chamfer 12 with the radius R, the entire region of the annular flange 6 and of the sealing surface 5 can be machined in such a way that the pre-existing chamfering 11 is removed completely, and the sealing surface 5 as well as the material of the spray-on layer 9 is removed completely from the annular flange. By virtue of the curvature R of the chamfer 12, the amount of material removed from the annular flange is minimized. The amount of material removal in this area should be minimized to ensure that the dead space (un-swept internal volume) in the cylinder is not increased unnecessarily, and that the formation of dead zones for combustion and mixing in the combustion chamber is minimized in the region of the chamfer 12.
To ensure that all the material of the spray-on layer 9 is reliably removed from the annular flange when the chamfer 12 is machined, the chamfer 12 may extend downward from sealing surface 5 into the cylinder liner 4, as indicated by depth C. This depth of the chamfer 12 can be seen at the parting line 13 extending around in the cylinder bore 3, which is the boundary line where the surface structure changes from the honed structure 10 to the bored structure 14 turned or bored all the way around, with the encircling score marks (indicated by horizontal lines) in the region of the curved chamfer 12, the bored structure 14 thereby giving an indication of the extent of the chamfer 12. The depth C of chamfer 12 preferably extends no lower than an upper-most end of the piston ring bearing surface of the bore.
The chamfer 12 may flare or curve radially outward (relative the cylinder bore axis), i.e. form a trumpet-shaped extension of the cylinder bore 3 toward the sealing surface 5 in the axial direction of the cylinder bore 3.
Given the dimensions shown, the chamfer 12 begins at the parting line 13 at a depth C of about 3.5 mm in the cylinder bore 3 and runs out upward and outward, so that the radius of the chamfer is about 0.1 mm larger at the sealing surface 5 than the original cylinder bore radius at the parting line 13.
A curved chamfer may also be used on engine blocks which do not have cylinder liners. In this liner-less case, the chamfer serves to clean the region of the transition from the cylinder bore to the sealing surface and, at the same time, as an assembly aid for the insertion of a piston into the cylinder bore. The curved chamfer provides a smooth transition, making it easier to introduce a piston into the cylinder bore.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.

## Claims

1. An engine block formed of a first material and having a sealing surface with respect to a cylinder head, the block defining a cylinder bore terminating axially at the sealing surface, the block comprising:
a bore liner within the cylinder bore and formed of a second material, an axial end of the liner spaced axially from the sealing surface to leave an annular inner bore surface of the first material exposed immediately adjacent the sealing surface; and
a curved chamfer around an inner circumference of the bore at a sealing surface end of the bore and extending into the annular inner bore surface and the end of the liner.

2. The block of claim 1, wherein the chamfer extends from the sealing surface into the cylinder bore to a depth of between approximately 2 mm and approximately 6 mm.

3. The block of claim 1, wherein the chamfer has a radius of curvature of between approximately 40 mm and approximately 100 mm.

4. The block of claim 1, wherein the first material is an aluminum alloy.

5. The block of claim 1, wherein the second material is cast iron.

6. A method of repairing a worn liner in an engine block cylinder bore, the block formed of a first material and having a sealing surface with respect to a cylinder head, and a top axial end of the liner spaced axially from the sealing surface to leave an annular inner bore surface of the first material exposed immediately adjacent the sealing surface, the method comprising:
machining the liner from a bottom axial end of the cylinder bore opposite from the top axial end to form an inlet surface terminating an axial distance from a top axial end of the bore adjacent to the sealing surface, the inlet surface having a diameter greater than a diameter of an un-machined portion of the bore adjacent to the top axial end of the bore;
spraying a repair coating onto the inlet surface and the annular inner bore surface;
machining the repair coating to a nominal bore diameter; and
forming a curved chamfer around a circumferential edge between the sealing surface end of the bore and the sealing surface, the chamfer extending axially into the liner.

7. The method of claim 6, wherein the chamfer is formed to extend from the sealing surface into the cylinder bore to a depth of between approximately 2 mm and approximately 6 mm.

8. The method of claim 6, wherein the chamfer is formed to have a radius of curvature of between approximately 40 mm and approximately 100 mm.