Laser surface alloying of aluminum engine bores

The current trend of using iron cylinder sleeves or liners in aluminum automotive engine blocks creates a costly manufacturing step that also negatively impacts engine performance, weight, and packaging. The potential to provide a cost-effective wear surface on aluminum engine blocks via laser surface alloying has been demonstrated and is presented in some detail. Previous work has examined the performance and manufacturing issues related to this critical automotive application, and the results presented here are shown to compare favorably with regard to performance requirements and manufacturing feasibility. Detailed dimensional characterization of the aluminum engine blocks was made before and after laser processing to determine the impact on cylindricity, straightness, and bore center location. These data show manufacturing feasibility for the process, and preliminary engine testing indicates adequate performance of chosen alloying materials and conditions. The objective of this paper is to discuss the...