Remanufactured Engine Piston Crown Bonding for Selective Repair
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Solution Overview
Problem
Internal combustion engine pistons often suffer premature damage due to harsh operating conditions, making them difficult to remanufacture and requiring premature replacement, as existing repair methods are inadequate and lack broad applicability.
Innovation Solution
A piston remanufacturing method involving a metallurgical bond between a piston body and an annular crown body, where the crown body is coupled to the piston body edge to form a joint, using techniques like laser beam welding or electron beam welding, allowing for the restoration of pistons to a state as good as new.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional repair methods (machining, welding repair parts) are used on damaged pistons, then some pistons can be repaired in certain instances, but the repair methods lack broad applicability and cannot successfully remanufacture pistons with diverse damage patterns or design variations
Solution Approach 1:
The piston is divided into two separable components: the piston body (containing the skirt and combustion chamber) and the crown body (containing the crown). This segmentation allows the crown body to be removed and replaced independently when damaged, while the piston body can be retained if still serviceable. The method enables selective replacement of only the damaged portion rather than requiring complete piston replacement or attempting complex repairs of the entire assembly.
Solution Approach 2:
The method discards the damaged crown body while recovering and reusing the piston body. The used piston body is separated from the damaged crown, and a new or remanufactured crown body is attached to the recovered piston body. This approach maximizes material utilization by keeping the serviceable portion (piston body) and replacing only the damaged portion (crown body).
2Power
If pistons are subjected to harsh operating conditions to meet engine performance requirements, then engine power and efficiency are improved, but the pistons suffer premature damage and require replacement before end of service life
Solution Approach 1:
The method enables recovery of the piston body from damaged pistons that would otherwise be discarded. By separating the serviceable piston body from the damaged crown body, the system recovers valuable material and extends the overall service life of piston components. The recovered piston bodies can be reused in new crown-body assemblies, reducing the need for complete piston replacements.
Solution Approach 2:
The remanufactured piston combines a recovered piston body (which may be aluminum alloy or iron) with a new or remanufactured crown body. This composite approach allows the piston to incorporate materials and designs optimized for different functional requirements: the piston body for structural support and the crown body for combustion exposure and performance characteristics.
3Reliability
If complete pistons are replaced when damage is detected, then reliable engine operation is maintained, but resource waste occurs and cost increases
Solution Approach 1:
The piston is segmented into replaceable crown body and retainable piston body components. This segmentation enables selective replacement of only the damaged crown body while preserving the serviceable piston body, thereby preventing the waste of functional materials. The method transforms the traditional all-or-nothing replacement approach into a targeted component replacement strategy.
Solution Approach 2:
The method recovers serviceable piston bodies from damaged pistons that would otherwise be completely discarded. By separating the valuable piston body from the damaged crown body, the system prevents material waste and reduces the need for virgin material production. The recovered piston bodies are reused in new assemblies, closing the material loop and reducing resource consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the effective remanufacturing of pistons, restoring them to a state with improved structural integrity and specifications, overcoming the limitations of existing repair methods by selectively replacing damaged material and using newly formed components.
Implementation Method 1
using techniques like laser beam welding or electron beam welding
Implementation Method 2
using techniques like laser beam welding or electron beam welding
Data Source
AI summary
A remanufactured piston for an internal combustion engine includes a crown and a skirt. A piston body includes a first piston body end within the crown and an opposite second piston body end. The crown further includes an annular crown body having an annular crown body edge. The first piston body end further includes an annular piston body edge. The annular piston body edge and the annular crown body edge form a joint, and a metallurgical bond attaches the annular crown body to the piston body at the joint.