Cylinder liners with adhesive metallic layers and methods of forming the cylinder liners

1. A method of manufacturing a coated cylinder liner, comprising the steps of:

providing a body including an outer surface and an inner surface, the inner surface extending from a first body end to a second body end, the inner surface surrounding a center axis to present a bore and a first opening at the first body end and a second opening at the second body end;

providing a sputtering device having end caps;

sealing the end caps against the body to form a deposition chamber in such manner that the inner surface of the body is exposed to the deposition chamber and a portion of the outer surface is exposed to the deposition chamber;

disposing a consumable metallic electrode in the bore of the body, the consumable metallic electrode being formed of metal;

sputtering the metal of the consumable metallic electrode onto the exposed inner surface of the body and the exposed portion of the outer surface.

2. The method of claim 1 including depositing a wear resistant component including a hydrocarbon over the inner surface after sputtering at least some of the metal of the consumable metallic electrode onto the inner surface.

3. The method of claim 2 including sputtering a mixture of a secondary component and the metal of the consumable metallic electrode over the inner surface after sputtering at least some of the metal of the consumable metallic electrode onto the inner surface and before depositing the wear resistant component over the inner surface.

4. The method of claim 1 wherein the consumable metallic electrode is solid and the metal of the consumable metallic electrode is selected from the group consisting of chromium and titanium.

5. The method of claim 1 wherein the consumable metallic electrode includes an electrode wall presenting a hollow opening and includes a plurality of orifices extending through the electrode wall; and including the step of providing a carrier gas through the hollow opening and orifices and into the deposition chamber.

6. A method of manufacturing a coated cylinder liner, comprising the steps of:

providing a body including an inner surface extending from a first body end to a second body end, the inner surface surrounding a center axis to present a bore and a first opening at the first body end and a second opening at the second body end, wherein the body includes an outer surface facing opposite the inner surface;

disposing a consumable metallic electrode in the bore of the body, the consumable metallic electrode being formed of metal;

sealing the first opening and the second opening to form a deposition chamber along the inner surface;

the step of sealing the second opening includes engaging a second seal with a portion of the outer surface of the body adjacent the second body end, and engaging the second seal with a second cover extending along the outer surface of the body and the second opening to seal the second opening while exposing a portion of the outer surface to the chamber; and

sputtering the metal of the consumable metallic electrode onto the inner surface of the body and onto the exposed portion of the outer surface.

7. The method of claim 6 including providing a vacuum pump through the second cover and into the deposition chamber for reducing the pressure in the deposition chamber;

applying a negative voltage to the consumable metallic electrode to form a plasma in the deposition chamber; and

providing a carrier gas including positively charged ions into the deposition chamber.

8. The method of claim 7 wherein the consumable metallic electrode includes an electrode wall presenting a hollow opening along the center axis and includes a plurality of orifices extending though the electrode wall; and wherein the step of providing the carrier gas includes providing the carrier gas through the hollow opening and orifices of the consumable metallic electrode and into the deposition chamber.

9. The method of claim 7 wherein the metal of the consumable metallic electrode is selected from the group consisting of chromium and titanium; and including the steps of

providing a secondary component in the carrier gas after sputtering at least some of the metal of the consumable metallic electrode onto the inner surface, the secondary component being nitrogen; and

providing at least one wear resistant component in the carrier gas after sputtering the secondary component, the wear resistant component including a hydrocarbon.

10. The method of claim 6 including spacing the second body end from the second cover such that the second body end and a portion of the outer surface of the body provide the deposition chamber.

11. The method of claim 6 , wherein the step of sealing the first opening includes disposing a first seal on the first body end, and disposing a first cover on the first seal to seal the first opening.

12. A method of manufacturing a coated cylinder liner, comprising the steps of:

providing a body including an inner surface extending from a first body end to a second body end, the inner surface surrounding a center axis to present a bore and a first opening at the first body end and a second opening at the second body end;

disposing a consumable metallic electrode in the bore of the body, the consumable metallic electrode being formed of metal;

sealing the first opening and the second opening to form a deposition chamber along the inner surface;

the step of sealing the second opening includes engaging a second seal with portion of the outer surface of the body adjacent the second body end, and engaging the second seal with a second cover extending along the outer surface of the body and the second opening to seal the second opening while exposing a portion of the outer surface to the deposition chamber;

providing at least one magnet along the consumable metallic electrode; and

magnetron sputtering the metal of the consumable metallic electrode onto the inner surface of the body and onto the exposed portion of the outer surface.

13. The method of claim 12 wherein the consumable metallic electrode includes an electrode wall presenting a hollow opening along the center axis and the at least one magnet is disposed in the hollow opening along the electrode wall.

14. A method of manufacturing a coated cylinder liner, comprising the steps of:

providing a body including an outer surface and including an inner surface extending from a first body end to a second body end, the inner surface surrounding a center axis to present a bore and a first opening at the first body end and a second opening at the second body end;

disposing a consumable metallic electrode in the bore of the body, wherein the consumable metallic electrode is formed of metal and includes an electrode wall presenting a hollow opening along the center axis and includes a plurality of orifices extending through the electrode wall;

providing a carrier gas through the hollow opening and orifices; and

sputtering the metal of the consumable metallic electrode onto the inner surface of the body and onto only portion of the outer surface of the body.

15. A method of forming a cylinder liner for receiving a piston of an internal combustion engine, comprising the steps of:

providing a body formed of a metal material extending circumferentially along a center axis and longitudinally between from a first body end to a second body end;

the body including an inner surface facing the center axis and extending longitudinally from the first body end to the second body end;

the inner surface presenting bore having a cylindrical shape between the first body end and the second body end;

the inner surface having an inner length extending from the first body end to the second body end;

the first body end presenting a first opening surrounding the center axis and having a circular shape;

the second body end presenting a second opening surrounding the center axis and having a circular shape;

the body presenting an outer surface facing opposite the inner surface and extending longitudinally from the first body end to the second body end;

the outer surface having an outer length extending from the first body end to the second body end;

the metal material of the body having a hardness of and of at least 20 HRC and a thermal conductivity of 40 to 50 W/(m·K);

the metal material being capable of withstanding extreme conductions during a typical combustion cycle;

the metal material of the body consisting of steel or a steel alloy;

disposing a consumable metallic electrode in the bore of the body along the center axis;

the consumable metallic electrode extending longitudinally along the center axis from a first electrode end to a second electrode end;

the consumable metallic electrode having a diameter less than the diameter of said inner surface to present a space therebetween;

the consumable metallic electrode consisting essentially of metal;

the metal of the consumable metallic electrode including at least one of chromium and titanium;

the consumable metallic electrode including an electrode wall presenting a hollow opening along the center axis and including a plurality of orifices extending through the electrode wall;

sealing the first opening and the second opening of the body to form a deposition chamber along the inner surface of the body;

the sealing step including disposing a first cover along the first body end and disposing a second cover along the second body end to form the deposition chamber, the covers being formed of steel, the first cover being a sheet, and the second cover being an open half-cylinder presenting an inner cover surface;

the sealing step including disposing a first seal on the first body end, the first seal being an O-ring formed of rubber and disposing the first cover on the first seal;

the sealing step including disposing the second body end in the open half-cylinder, disposing a second seal around the outer surface of the body adjacent the second body end, the second seal being an O-ring formed of rubber, and engaging the second seal with the inner cover surface of the second cover to seal the deposition chamber, the second cover extending across the second opening;

spacing the second body end from the second cover such that the second body end and a portion of the outer surface of the body provide the deposition chamber;

securing the first cover and the body in place relative to one another;

providing a gas inlet extending through the first cover and into the deposition chamber for providing a carrier gas into the deposition chamber;

providing a vacuum pump extending through the second cover to the deposition chamber for reducing the pressure in the deposition chamber;

providing a vacuum gage extending through the second cover to the deposition chamber for measuring the pressure in the deposition chamber;

providing a power supply for applying a negative voltage to the first electrode end of the consumable metallic electrode;

interconnecting the power supply and the first electrode end by an electrically isolating feed-through, the electrically insulating feed-through extending through the first cover;

applying a negative voltage to the first electrode end to provide plasma in the deposition chamber, the voltage being provided by the power supply and being pulsed, and the voltage being a radio frequency (RF) voltage or a direct current (DC) voltage;

supplying a carrier gas including positively charged ions through the hollow opening and orifices and into the sealed deposition chamber, the positively charged ions including at least one of argon (Ar) and hydrogen (H2);

sputtering the metal of the consumable metallic electrode onto the inner surface of the body;

the sputtering step including forming a metallic adhesive layer consisting of the metal of the consumable metallic electrode on the inner surface of the body, the metallic adhesive layer having a thickness varying by not more than 5% along at least 70% of the inner length;

increasing the pressure of the deposition chamber to adjust the amount of metal sputtered onto the inner surface of the body;

adjusting the amount of carrier gas supplied to the deposition chamber to adjust the amount of metal sputtered onto the inner surface of the body;

the sputtering step including disposing the metallic adhesive layer on at least a portion of the first body between the inner surface and the first seal and disposing the metallic adhesive layer on the second body end and along 1 to 40% of the outer length adjacent the second body end; and

providing at least one wear resistant component through the gas inlet into the deposition chamber and depositing the wear resistant component onto the metallic adhesive layer to form a wear resistant layer, the at least one wear resistant component including a hydrocarbon and at least one of silicon and germanium, and the wear resistant layer having a thickness varying by not more than 5% along at least 70% of the inner length.