US010471554B2

United States Patent ( 10 ) Patent No.: US 10,471,554 B2

Graham et al. (45 ) Date of Patent: Nov. 12 , 2019
(54 ) FUEL INJECTOR BORE REPAIR (58 ) Field of Classification Search
CPC .. B23P 6/02; B23P 6/04 ; B23P 19/043 ; B23P
(71) Applicant: Caterpillar Inc., Peoria , IL (US) 6/00 ; C23C 24/04 ; FO2B 23/0627 ; FO2F
3/14 ; F02F 1/24 ; F02F 11/02; FO2M
( 72 ) Inventors : Curtis John Graham , Peoria, IL (US); 61/14 ; FO2M 51/061; FO2M 2200/8015
Robert E. Sharp , Corinth , MS (US); See application file for complete search history .
Daniel Thomas Cavanaugh ,
Chillicothe, IL (US); Robert Louis (56 ) References Cited
Brockman , Michie , TN (US )
U.S. PATENT DOCUMENTS
(73 ) Assignee : Caterpillar Inc., Peoria , IL (US )
7,458,358 B2 12/2008 Lineton et al .
( * ) Notice: Subject to any disclaimer, the term of this 8,486,249 B2 7/2013 Almond et al.
patent is extended or adjusted under 35 8,601,663 B2 12/2013 Ngo et al.
9,574,536 B2 * 2/2017 Oohata FO2M 61/14
U.S.C. 154(b ) by 136 days. 2004/0020469 A1 * 2/2004 Reiter FO2M 61/14
123/470
(21) Appl. No .: 15 /682,813 2012/0217323 A1 * 8/2012 Martinsson B21D 53/84
239 /533.2
(22 ) Filed : Aug. 22 , 2017 2014/0115854 Al 5/2014 Widener et al .
2015/0020386 A1 * 1/2015 Shaw FO2F 1/242
(65 ) Prior Publication Data
2017/0363054 A1 * 12/2017 Pickard
29 /888.011
FO2M 61/14
US 2019/0061072 A1 Feb. 28 , 2019
* cited by examiner
(51) Int. Ci.
B23P 6/02 ( 2006.01) Primary Examiner Syed O Hasan
B23P 6/04 (2006.01) (74 ) Attorney, Agent, or Firm - Law Office of Kurt J.
B23P 19/04 (2006.01) Fugman LLC
C23C 24/04 ( 2006.01)
F02B 23/06 ( 2006.01 ) (57 ) ABSTRACT
F02F 3/14 (2006.01 ) A method for remanufacturing or repairing a cylinder head
C23C4/01 (2016.01) having a bore configured to receive a fuel injector comprises
C23C 4/18 ( 2006.01 ) machining a portion of a surface forming the bore to remove
(52) U.S. CI. imperfections, inserting a repair component into the bore
CPC B23P 6/02 ( 2013.01 ); B23P 6/04 proximate the machined portion of the bore , and spraying
( 2013.01) ; B23P 19/043 (2013.01 ); C230 material into the bore proximate the machined portion and
24/04 (2013.01 ); F02B 23/0627 (2013.01); the repair component, thereby holding the component into
F02F 3/14 (2013.01 ); C23C 4/01 (2016.01); place .
C23C 4/18 (2013.01); FO2M 2200/8076
(2013.01) 16 Claims, 7 Drawing Sheets

200 100 , 102

116
208

114
-202 - 112
-206
204

106
U.S. Patent Nov. 12 , 2019 Sheet 1 of 7 US 10,471,554 B2

102
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100
208 112 206 106
204
200
202
2
.
FIG

104

114
116

102
,
100 108 114 112
110
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104
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FIG
1

116
U.S. Patent Nov. 12 , 2019 Sheet 2 of 7 US 10,471,554 B2

100 , 102
104 200

118

206

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106 , 120

FIG . 3
U.S. Patent Nov. 12 , 2019 Sheet 3 of 7 US 10,471,554 B2

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U.S. Patent Nov. 12 , 2019 Sheet 4 of 7 US 10,471,554 B2

104 100 , 102

200 124
218
108

214 216 208

206
110
110
200

125

FIG . 5
U.S. Patent Nov. 12 , 2019 Sheet 5 of 7 US 10,471,554 B2

118
102
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108
208
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U.S. Patent Nov. 12 , 2019 Sheet 6 of 7 US 10,471,554 B2

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104 200
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312
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308 306

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FIG . 7
U.S. Patent Nov. 12 , 2019 Sheet 7 of 7 US 10,471,554 B2

START 402 410

420 THE REPAIR

MACHININGAPORTION OF A SURFACE COMPONENT ISA
FORMING THE BORE TO REMOVE REPAIR SLEEVE
IMPERFECTIONS DEFINING AN
MACHINED PORTION OF THE INSIDE CYLINDRICAL
BORE HAS SURFACE FINISH SURFACE THAT
OF 3.2u Ra OR MORE MATCHES ANOTHER
INSIDE CYLINDRICAL
INSERTING A REPAIR COMPONENT INTO
THE BORE PROXIMATE THE MACHINED
PORTION OF THE BORE THE REPAIR
404 COMPONENT
CONTACTS AT LEAST
A PORTION OF THE
MACHINED
PORTION OF THE
SPRAYING MATERIAL INTO THE BORE BORE
PROXIMATE THE MACHINED PORTION

416
AND THE REPAIR COMPONENT, THEREBY
HOLDING THE COMPONENT INTO PLACE
SPRAYING IS
PERFORMED BY
408
5
INSERTING A SPRAY
THE SPRAYED MATERIALIS NOZZLE WITHIN 14 OF
HARDENED . CURED OR AN INCH TO 12 OF AN
SOLIDIFIED TO HOLD THE INCH OF THE MACHINED
REPAIR COMPONENT INTO PORTION
PLACE

FORMING AN UNDERCUT OF 418

THE REPAIR COMPONENT 412
RELATIVE TO THE SPRAYED
MATERIAL ALONGA
DIRECTION OF
DISASSEMBLY, THEREBY THE BORE INCLUDES
PREVENTING THE REPAIR METAL COLD SPRAY
COMPONENT FROM BEING MATERIAL FORMING
REMOVED FROM THE BORE A CHAMFERED
PORTION OF THE BORE
414
FIG . 8
 US 10,471,554 B2
1 2
FUEL INJECTOR BORE REPAIR an intermediate diameter portion of the bore disposed axially
between the large diameter portion of the bore and the small
TECHNICAL FIELD diameter portion of the bore, the body further defining a
machined chamfered portion extending axially from the
The present disclosure relates generally to fuel injector 5 oflargethediameter
bores disposed in cylinder heads that are configured to house
portion of the bore to the intermediate portion
bore . The body may further define a machined step
a fuel injector. More specifically , the present disclosure disposed axially between the large diameter portion of the
relates to a method of remanufacturing, refurbishing or bore and the chamfered portion of the bore .
repairing such fuel injector fuel injector bores so that seals A cylinder head assembly according to an embodiment of
located between the fuel injector and the fuel injector bore 10 the present disclosure is provided including a cylinder head
are able to prevent fluid leakage. configured to receive a fuel injector. The cylinder head may
comprise a body defining a bore having a longitudinal axis
BACKGROUND and configured to receive a fuel injector. The body also
defining a large diameter portion of the bore, a small
Fuel injectors are routinely housed in the fuel injector 15 diameter portion of the bore and an intermediate diameter
bore of a cylinder head that is configured to closely match portion of the bore disposed axially between the large
the outside shape of the fuel injector. Seals are disposed at diameter portion of the bore and the small diameter portion
one or more places between the outside housing of the fuel of the bore. The body may further define a machined
injector and the inside surface of the fuel injector bore of the chamfered portion extending axially from the large diameter
cylinder to prevent the leakage of fuel into the water jacket 20 portion of the bore to the intermediate portion of the bore
of the cylinder head . Over time, the areas located adjacent and a machined step disposed axially between the large
the seals on the inside surface of the fuel injector bore may diameter portion of the bore and the chamfered portion of
become worn or pitted , which may reduce the effectiveness the bore. A fuel injector may be disposed in the bore of the
of the seals to prevent leakage of the fuel into the water cylinder head.
jacket. More particularly , fuel may seep into the areas 25 A method for remanufacturing or repairing a cylinder
between the fuel injector and the surfaces of the bore of the head having a bore configured to receive a fuel injector
cylinder head , which along with heat, may produce pitting of according to an embodiment of the present disclosure is
the surfaces because of the corrosive nature of the sulfur in provided . The method may comprise machining a portion of
the fuel catalyzed by the heat, negatively impacting the a surface forming the bore to remove imperfections, insert
effectiveness of seal in that area. Eventually, a leak may 30 ing a repair component into the bore proximate the
occur and this may lead to the engine malfunctioning , machined portion of the bore, and spraying material into the
necessitating repair and maintenance and an associated bore proximate the machined portion and the repair com
economic loss for the industrial endeavor using the engine. ponent, thereby holding the component into place.
Of course , it may be difficult and/ or expensive to repair or
replace the cylinder head . One known method for repairing 35 BRIEF DESCRIPTION OF THE DRAWINGS
threaded components is disclosed by U.S. Pat. No. 8,601,
663 to Ngo et al. As shown by the abstract ofNgo , this patent FIG . 1 is a cut-away side view of a fuel injector bore of
is directed to repairing damage to an internally threaded a cylinder head with eroded areas machined away according
opening .More specifically, methods are provided for struc to various embodiments of the present disclosure .
turally repairing a component having a damaged internally 40 FIG . 2 is a cut-away side view of the fuel injector bore of
threaded opening . The damaged internally threaded opening the cylinder head of FIG . 1 showing a repair sleeve being
is machined to a predetermined diameter, thereby forming a inserted in a counterbore adjacent the machined surfaces.
machined opening. At least one notch is formed in the FIG . 3 is a cut-away side view of the fuel injector bore of
machined opening, thereby forming a notched opening. A the cylinder head of FIG . 2 where a metal cold spray process
selected amount of repair material is cold sprayed into the 45 has been applied to the machined chamfered area above the
notched opening, including into the at least one notch . A repair sleeve.
plurality of internal threads is formed from the repair FIG . 4 is an enlarged detail view of the fuel injector bore
material to form a repaired internally threaded opening in of the cylinder head of FIG . 3, showing more clearly the
the component. The repaired components are also provided . interface between the repair sleeve and the metal cold spray
However, this process does not teach how to provide a 50 deposited material and the profile of metal cold spray
suitable repair so that a fluid tight sealmay be provided and deposited material.
maintained in a harsh environment such as an engine where FIG . 5 is a cut-away side view of the fuel injector bore of
temperatures and corrosive agents may be present. the cylinder head of FIG . 3 after the metal cold spray
Accordingly , it is desirable to develop a method and deposited material and the repair sleeve have been machined
apparatus that may allow the user of an engine to remanu- 55 to match the original dimensions of the fuel injector bore of
facture , refurbish or otherwise repair the fuel injector bore of the cylinder head .
a cylinder head that may house a fuel injector and provide FIG . 6 is an enlarged detail view of the fuel injector bore
a fluid tight seal between the fuel injector and the cylinder of the cylinder head of FIG . 5 , showing more clearly the
head in a reliable and economic manner . interface between the repair sleeve and the metal cold spray
60 deposited material and the profile of the metal cold spray
SUMMARY OF THE DISCLOSURE deposited material after the finished machining operation
has been completed .
A cylinder head according to an embodiment of the FIG . 7 is cut-away side view showing the fuel injector
present disclosure is provided comprising a body defining a bore of the cylinder head of FIG . 5 with a fuel injector
bore having a longitudinal axis and configured to receive a 65 inserted into the bore and a seal contacting the repaired
fuel injector, the body may also define a large diameter section of the fuel injector bore and the housing of the fuel
portion of the bore, a small diameter portion of the bore and injector, providing a fluid tight seal.
 US 10,471,554 B2
3 4
FIG . 8 is a flow chart containing a method for remanu mediate diameter portion 112 , wherein the repair sleeve 200
facturing, refurbishing or repairing a fuel injector bore of a includes an annular cylindrical shape defining a cylindrical
cylinder head and reinstalling a fuel injector into the bore axis 202 , a first end 204 disposed along the cylindrical axis
while providing a fluid tight seal according to an embodi 202 having a chamfered portion 206 and a second end 208
ment of the present disclosure . 5 disposed along the cylindrical axis 202. The cylindrical axis
DETAILED DESCRIPTION
202 may be coextensive with the longitudinal axis 106 of the
bore 104 .
In some embodiments, such as that shown in FIG . 4 , the
Reference will now be made in detail to embodiments of second end 208 of the repair sleeve 200 also has a chamfered
the disclosure, examples of which are illustrated in the 10 portion 210. In many embodiments , the repair sleeve 200
accompanying drawings. Wherever possible , the same ref may be symmetrical about a midplane 212 positioned half
erence numbers will be used throughout the drawings to way along
refer to the same or like parts . In some cases , a reference In still othertheembodiments
cylindrical axis 202 of the repair sleeve 200 .
, the repair sleeve 200 is inserted
number will be indicated in this specification and the draw
ings will show the reference number followed by a letter for 15 with
into the intermediate diameter portion 112 of the bore 104
a slight interference fit such as between 0.0005 of an
example, 100a ,100b or a prime indicator such as 100', 100"
etc. It is to be understood that the use of letters or primes inch to 0.0015 of an inch depending on the size of the outer
immediately after a reference number indicates that these diameter 214 of the repair sleeve 200. Furthermore, the
features are similarly shaped and have similar function as is interference fit may be designed in accordance with ISO
often the case when geometry is mirrored about a plane of 20 standards for slight interference fits . In many embodiments,
symmetry . For ease of explanation in this specification, the intermediate diameter portion 112 is formed by a coun
letters or primes will often not be included herein but may terbore 113 with a flat bottom surface 115 and the repair
be shown in the drawings to indicate duplications of features sleeve 200 is inserted until the first end 204 of the repair
discussed within this written specification . sleeve 200 contacts or nearly contacts the flat bottom surface
A method for repairing a cylinder head , the resulting 25 115. The chamfered portion 206 of the first end 204 of the
cylinder head, or other similar component and the associated repair sleeve 200 is positioned toward the outside of the
cylinder head assembly with a fuel injector installed or repair sleeve 200 , helping to prevent corner interference
uninstalled according to various embodiments of the present with the counterbore 113 , allowing the repair sleeve 200 to
disclosure will now be described . While the application be fully seated . The materialof the repair sleeve 200 may be
discussed herein is primarily a cylinder head used with large 30 stainless steel or any other suitably durable and corrosion
engines, it is to be understood that in other embodiments that resistant material.
any sized cylinder head using any type of fuel injector may Turning now to FIG . 3 , some metal cold spray material
be used and / or benefit from the embodiments discussed 118 may be attached the chamfered portion 114 of the
herein . Similarly , the type of fuel injected by the injector bore 104 of the cylinder head 100 and the repair sleeve 200,
may be varied and includes diesel fuel, gasoline , etc. 35 helping to prevent the removal of the repair sleeve 200 from
Accordingly, the applications of the embodiments discussed the bore 104 of the cylinder head 100 along a direction of
herein are applicable to a host of engine types and to a host disassembly 120 , which is also substantially along the
of machines driven by such engines . longitudinal axis 106 of the bore 104. As best seen in FIG .
Looking at FIG . 1 , a cylinder head configured to receive 4 , the metal cold spray material 118 may bulge slightly into
a fuel injector according to an embodiment of the present 40 the bore 104 and may also contact the chamfered portion 210
disclosure is illustrated . The cylinder head 100 comprises a positioned toward the outside of the second end 208 of the
body 102 defining a bore 104 having a longitudinal axis 106 repair sleeve 200 , forming an undercut 122 configured to
and that is configured to receive a fuel injector 302 (only prevent removal of the repair sleeve 200. The metal cold
shown in FIG . 7 ). The bore 104 of the body 102 also defines spray material 118 may be stainless steel,a nickel-aluminum
a large diameter portion 108 of the bore 104 , a small 45 alloy (e.g. 95 % nickel and 5 % aluminum ) or any other
diameter portion 110 of the bore 104 and an intermediate sufficiently durable and corrosion resistant material . Any
diameter portion 112 of the bore 104 disposed axially standard high pressure spray nozzle and associated systems
between the large diameter portion 108 of the bore 104 and may be used to lay down the metal cold spray material. In
the small diameter portion 110 of the bore 104. The body some embodiments , the spray nozzle may be placed within
102 further defines a machined chamfered portion 114 50 a quarter of an inch to half an inch of the area where the
extending axially from the large diameter portion 108 of the material is desired to be deposited ( e.g. the machined
bore 104 to the intermediate portion 112 of the bore 104. chamfered portion 114 of the bore 104 ).
Furthermore , the body 102 further defines a machined step Looking now at FIGS. 5 and 6 , the repair sleeve 200
116 (best seen in FIG . 6 ) disposed axially between the large defines an inside cylindrical surface 216 and the metal cold
diameter portion 108 of the bore 104 and the chamfered 55 spray material 118 is machined to create a finished machined
portion 114 of the bore 104. The machining helps to remove chamfered portion 124 that smoothly transitions to the large
imperfections such as pitting, erosion , damage etc. that may diameter portion 108 of the bore 104 , and the inside cylin
have occurred over time to the surfaces of the bore 104 . drical surface 216 is finish machined to be coextensive with
Machining may include milling , EDM (electrical discharge the small diameter cylindrical portion 110. More specifi
machining ), etc. 60 ?ally, the small diameter cylindrical portion 110 defines a
In some embodiments , the machined step 116 and the small inside cylindrical surface 126 that would be coexten
machined chamfered portion 114 include surfaces having a sive with the inside cylindrical surface 216 of the repair
surface roughness with a Ra value of 3.2 microns or greater sleeve 200 after being finish machined . Also , the inside
to allow better adherence of sprayed material as will be portion 218 of the second end 208 of the repair sleeve 200
further described later herein . 65 is also finish machined to provide a smooth transition from
Referring now to FIG . 2 , the cylinder head 100 may the chamfered portion 124 of the sprayed material 118 to the
further comprise a repair sleeve 200 inserted into the inter inside cylindrical surface 216 of the repair sleeve 200 .
 US 10,471,554 B2
5 6
Focusing now on FIG . 7, a cylinder head assembly 300 In some embodiments, the machined step 116 and
that may be part of an engine according to an embodiment machined chamfered portion 114 include surfaces having a
of the present disclosure will now be described . The cylinder surface roughness with a Ra value of 3.2 microns or greater
head assembly 300 may include a cylinder head 100 and to allow better adherence of sprayed material as will be
repair sleeve 200 as previously described with respect to 5 further described later herein .
FIGS. 1 thru 6. Specifically, the cylinder head 100 may be Referring again to FIG . 2, the cylinder head 100 may
configured to receive a fuel injector 302 and may include a further comprise a repair sleeve 200 inserted into the inter
body 102 defining a bore 104 having a longitudinal axis 106 mediate diameter portion 112, wherein the repair sleeve 200
includes an annular cylindrical shape defining a cylindrical
and may be configured to receive a fuel injector 302. The 10 axis 202, a first end 204 disposed along the cylindrical axis
bore 104 of the body 102 may also define a large diameter 202 having a chamfered portion 206 and a second end 208
portion 108 of the bore 104 , a small diameter portion 110 of disposed along the cylindrical axis 202. The cylindrical axis
the bore 104 and an intermediate diameter portion 112 of the 202 may be coextensive with the longitudinal axis 106 of the
bore 104 disposed axially between the large diameter por bore 104. In some embodiments, such as that shown in FIG .
4 , the second end 208 of the repair sleeve 200 also has a
tion 108 of the bore 104 and the small diameter portion 110 15 chamfered
of the bore 104. The bore 104 may have a machined sleeve 200 portion may be
210. In many embodiments, the repair
symmetrical about a midplane 212
chamfered portion 114 extending axially from the large positioned half way along the cylindrical axis 202 of the
diameter portion 108 of the bore 104 to the intermediate repair sleeve 200. In still other embodiments, the repair
diameter portion 112 of the bore 104 with a machined step sleeve 200 is inserted into the intermediate diameter portion
116 disposed axially between the large diameter portion 108 20 112 of the bore 104 with a slight interference fit such as
of the bore 104 and the chamfered portion 114 of the bore between 0.0005 of an inch to 0.0015 of an inch depending
104. This structure may be seen by sectioning the cylinder on the outer diameter 214 of the repair sleeve 200. In other
head 100 along a midplane of the bore 104 , revealing the embodi ents , a slip fit may be provided . When an interfer
structure of FIG . 7 . ence fit is employed , the interference fit may be designed in
A fuel injector 302 may be disposed in the bore 104 with 25 accordance with ISO standards for slight interference fits .
the front portion or tip 304 of the housing 306 of the fuel The material of the repair sleeve 200 may be stainless steel
injector 302 contacting the angled bottom surface 128 of the or any other suitably durable and corrosion resistant mate
bore 104. The rest of the housing 306 of the fuel injector 302 rial.
may be slightly spaced away or may be provided with a Referring back again to FIG . 3 , some metal cold spray
slight gap 308 between the housing 306 of the fuel injector 30 material 118 may be attached to the chamfered portion 114
302 and the various surfaces of the bore 104 of the cylinder of the bore 104 of the cylinder head 100 and the repair sleeve
head 100. As alluded to earlier herein , the repair sleeve 200 200, helping to prevent the removal of the repair sleeve 200
defines an inside cylindrical surface 216 , the small diameter from the bore 104 of the cylinder head 100 along a direction
portion 110 of the bore 104 defines a small inside cylindrical of disassembly 120 , which is also substantially along the
surface 126 and the metal cold spray material 118 is finish 35 longitudinal axis 106 of the bore 104. As best seen in FIG .
machined to create a finish machined chamfered portion 124 4 , the metal cold spray material 118 may bulge slightly into
that smoothly transitions to the large diameter portion 108 of the bore 104 and may also contact the chamfered portion 114
the bore 104, and the inside cylindrical surface 216 is finish of the second end 208 of the repair sleeve 200 , forming an
machined to be coextensive with the small inside cylindrical undercut 122 configured to prevent removal of the repair
surface 126 of the small diameter cylindrical portion 110 of 40 sleeve 200. The cold spray material 118 may be stainless
the bore 108. A seal 310 is sandwiched between the housing steel, a nickel-aluminum alloy ( e.g. 95 % nickel and 5 %
306 of the fuel injector 302 and the inside cylindrical surface aluminum ) or any other sufficiently durable and corrosion
216 of the repair sleeve 200, providing a fluid tight seal. For resistantmaterial. Any standard high pressure spray nozzle
this embodiment, the seal 310 is an o - ring that is situated in and associated systemsmay be used to lay down the metal
an o -ring groove 312 formed by the housing 306 of the fuel 45 cold spray material. In some embodiments, the spray nozzle
injector 302. Other types of seals may be used and may be may be placed within a quarter of an inch to half an inch of
held in place using other configurations of the repair sleeve the area where the material is desired to be deposited .
200 and/or the housing 306 . Looking again at FIGS. 5 and 6 , the repair sleeve 200
Referring back to FIG . 1, the cylinder head 100 comprises defines an inside cylindrical surface 216 and the metal cold
a body 102 defining a bore 104 having a longitudinal axis 50 spray material 118 is finish machined to create a finish
106 and that is configured to receive a fuel injector 302. The machined chamfered portion 124 that smoothly transitions
bore 104 of the body 102 also defines a large diameter to the large diameter portion 108 of the bore 104, and the
portion 108 of the bore 104 , a small diameter portion 110 of inside cylindrical surface 216 is finish machined to be
the bore 104 and an intermediate diameter portion 112 of the coextensive with the small diameter cylindrical portion 110 .
bore 104 disposed axially between the large diameter por- 55 More specifically , the small diameter cylindrical portion 110
tion 108 of the bore 104 and the small diameter portion 110 defines a small inside cylindrical surface 126 that would be
of the bore 104. The body 102 further defines a machined coextensive with the inside cylindrical surface 216 of the
chamfered portion 114 extending axially from the large repair sleeve 200 after finish machining. Also , the inside
diameter portion 108 of the bore 104 to the intermediate portion 218 of the second end 208 of the repair sleeve 200
diameter portion 112 of the bore 104. Furthermore,thebody 60 is also finish machined to provide a smooth transition from
102 further defines a machined step 116 (best seen in FIG . the chamfered portion 124 of the sprayed material 118 to the
6 ) disposed axially between the large diameter portion 108 inside cylindrical portion 216 of the repair sleeve 200 .
of the bore 104 and the chamfered portion 114 of the bore
104. The machining helps to remove imperfections such as INDUSTRIAL APPLICABILITY
pitting, erosion , damage etc. that may have occurred over 65
time to the surfaces of the bore and may be performed using In practice , a repair component such as a repair insert or
the processes discussed elsewhere herein . sleeve , a cylinder head , a cylinder head assembly and /or an
 US 10,471,554 B2
7 8
engine assembly according to any embodiment described be constructed and function differently than what has been
herein may be provided , sold ,manufactured , and bought etc. described herein and certain steps of any method may be
to refurbish , retrofit or remanufacture existing engines, omitted , performed in an order that is different than what has
cylinder heads, cylinder head assemblies as needed or been specifically mentioned or in some cases performed
desired in an aftermarket or OEM context. 5 simultaneously or in sub -steps. Furthermore , variations or
FIG . 8 is a method 400 for remanufacturing or repairing modifications to certain aspects or features of various
a cylinder head having a bore configured to receive a fuel embodiments may be made to create further embodiments
injector, themethod 400 comprising: machining a portion of and features and aspects of various embodiments may be
a surface forming the bore to remove imperfections (step added to or substituted for other features or aspects of other
402 ), inserting a repair component into the bore proximate 10 embodiments in order to provide still further embodiments.
the machined portion of the bore (step 404 ), and spraying Accordingly, this disclosure includes all modifications
material into the bore proximate the machined portion and and equivalents of the subject matter recited in the claims
the repair component, thereby holding the component into appended hereto as permitted by applicable law .Moreover,
place ( step 406 ). any combination of the above -described elements in all
In some embodiments , the repair component contacts at 15 possible variations thereof is encompassed by the disclosure
least a portion of the machined portion of the bore (step unless otherwise indicated herein or otherwise clearly con
408 ). tradicted by context.
In some embodiments , the repair component is a repair What is claimed is :
sleeve defining an inside cylindrical surface that matches 1. A cylinder head configured to receive a fuel injector
another inside cylindrical surface of the bore ( step 410 ). 20 comprising: a body defining a bore having a longitudinal
In certain embodiments, the bore includes metal cold axis and configured to receive a fuel injector; the body also
spray material forming a chamfered portion of the bore (step defining a large diameter portion of the bore, a small
412). This chamfered portion may be provided after spray diameter portion of the bore and an intermediate diameter
ing, hardening and machining the sprayed material. portion of the bore disposed axially between the large
In some embodiments , the method further comprises 25 diameter portion of the bore and the small diameter portion
forming an undercut of the repair component relative to the of the bore, the body further defining a machined chamfered
sprayed material along a direction of disassembly, thereby portion extending axially from the large diameter portion of
preventing the repair component from being removed from the bore to the intermediate diameter portion of the bore ; and
the bore (step 414 ). wherein the body further defines a machined step disposed
The sprayed material may be hardened , cured or solidified 30 axially between the large diameter portion of the bore and
in order to hold the repair component in place after the the machined chamfered portion of the bore; a repair sleeve
material has been sprayed ( step 416 ). inserted into the intermediate diameter portion , wherein the
During the spraying step , the spray nozzle may be inserted repair sleeve includes an annular cylindrical shape defining
to be within a quarter of an inch to half an inch of the a cylindrical axis , a first end disposed along the cylindrical
machined portion of the bore (step 418). 35 axis having a chamfered portion and a second end disposed
After machining a portion of the surface forming the bore along the cylindrical axis and also having a chamfered
to remove imperfections, the machined portion of the bore portion ; and a metal material attached to the machined
may have a surface finish of 3.2 microns Ra or more to help chamfered portion of the bore of the cylinder head and the
improve the adherence of the sprayed material to the surface chamfered portion of the second end of the repair sleeve ,
of the bore (step 420 ). 40 forming an undercut configured to prevent removal of the
It will be appreciated that the foregoing description pro repair sleeve.
vides examples of the disclosed assembly and technique . 2. The cylinder head of claim 1, wherein the machined
However , it is contemplated that other implementations of step and machined chamfered portion includes surfaces
the disclosure may differ in detail from the foregoing having a surface roughness with a Ra value of 3.2 microns
examples. All references to the disclosure or examples 45 or greater.
thereof are intended to reference the particular example 3. The cylinder head of claim 1, wherein the repair sleeve
being discussed at that point and are not intended to imply is inserted into the intermediate diameter portion of the bore
any limitation as to the scope of the disclosure more gen with a slight interference fit .
erally . All language of distinction and disparagement with 4. The cylinder head of claim 1 , wherein the metal
respect to certain features is intended to indicate a lack of 50 material includes a metal cold spray material .
preference for those features , but not to exclude such from 5. The cylinder head of claim 4 , wherein the repair sleeve
the scope of the disclosure entirely unless otherwise indi defines an inside cylindrical surface, the small diameter
cated . cylindrical portion defines a small inside cylindrical surface
Recitation of ranges of values herein are merely intended and the metal cold spray material is finish machined to create
to serve as a shorthand method of referring individually to 55 a finish machined chamfered portion that smoothly transi
each separate value falling within the range , unless other tions to the large diameter portion of the bore, and the inside
wise indicated herein , and each separate value is incorpo cylindrical surface is finish machined to be coextensive with
rated into the specification as if it were individually recited the small inside cylindrical surface of the small diameter
herein . cylindrical portion.
It will be apparent to those skilled in the art that various 60 6. A cylinder head assembly comprising : a cylinder head
modifications and variations can be made to the embodi configured to receive a fuel injector comprising: a body
ments of the apparatus and methods of assembly as dis defining a bore having a longitudinal axis and configured to
cussed herein without departing from the scope or spirit of receive a fuel injector ; the body also defining a large
the invention (s ). Other embodiments of this disclosure will diameter portion of the bore, a small diameter portion of the
be apparent to those skilled in the art from consideration of 65 bore and an intermediate diameter portion of the bore
the specification and practice of the various embodiments disposed axially between the large diameter portion of the
disclosed herein . For example , someof the equipment may bore and the small diameter portion of the bore, the body
 US 10,471,554 B2
9 10
further defining a machined chamfered portion extending cold metal spray material that contacts the repair sleeve
axially from the large diameter portion of the bore to the and the machined chamfered portion of the bore ; and
intermediate diameter portion of the bore; wherein the body a seal disposed between the fuel injector and the repair
further defines a machined step disposed axially between the sleeve .
large diameter portion of the bore and the machined cham- 5 12. A method for remanufacturing or repairing a cylinder
fered portion of the bore; a repair sleeve inserted into the head having a bore configured to receive a fuel injector, the
intermediate diameter portion , wherein the repair sleeve method comprising :machining a portion of a surface form
includes an annular cylindrical shape defining a cylindrical ing the bore in a body of the cylinder head to remove
axis, a first end disposed along the cylindrical axis having a imperfections
chamfered portion and a second end disposed along the 10 an intermediate, thediameter body having each of a large , a small, and
portion of the bore, the interme
cylindrical axis and also having a chamfered portion ; a metal diate diameter portion disposed
material attached to the machined chamfered portion of the and small diameter portions, and axially the body
between the large
further having a
bore of the cylinder head and the chamfered portion of the machined chamfered portion extending axially from the
second end of the repair sleeve , forming an undercut con
figured to prevent removal of the repair sleeve; and a fuel 15 and
largeadiameter portion to the intermediate diameter
machined step disposed axially between the large
portion ,
injector disposed in the bore of the cylinder head .
7. The cylinder head assembly of claim 6, wherein the diameter portion and themachined chamfered portion of the
machined step and machined chamfered portion includes bore ; inserting a repair sleeve component into the interme
diate diameter portion of the bore proximate the machined
surfaces having a surface roughness with a Ra value of 3.2 portion of the bore, the repair sleeve including an annular
microns or greater. 20
cylindrical shape defining a cylindrical axis , a first end
8. The cylinder head assembly of claim 6 , wherein the disposed along the cylindrical axis having a chamfered
repair sleeve is inserted into the intermediate diameter portion and a second end disposed along the cylindrical axis
portion of the bore with a slight interference fit.
9. The cylinder head assembly of claim 6 , wherein the material into the bore proximateportion
and also having a chamfered
the
; and spraying metal
machined portion and
metalmaterial includes a metal cold spray material. 25
the repair component, to attach the machined chamfered
10. The cylinder head assembly of claim 9 , wherein the portion of the bore of the cylinder head to the chamfered
repair sleeve defines an inside cylindrical surface, the small
diameter portion of the bore defines a small inside cylindri portion of the second end of the repair sleeve component and
forming an undercut preventing removal of the repair sleeve.
cal surface and the metal cold spray material is finish 13. Themethod of claim 12 wherein therepair component
machined to create a finish machined chamfered portion that 30 contacts
smoothly transitions to the large diameter portion of the bore . at least a portion of the machined portion of the
bore , and the inside cylindrical surface is finish machined to 14. The method of claim 13 , wherein the repair sleeve
be coextensive with the small inside cylindrical surface of defining an inside cylindrical surface that matches another
the small diameter cylindrical portion .
11. The cylinder head assembly of claim 6 , further com- 35 15. The methodsurface
inside cylindrical
of
of the bore .
claim 13 , wherein the metal material
prising : includes metal cold spray material .
a repair sleeve inserted into the intermediate diameter 16. The method of claim 13 , wherein the undercut is
cylindrical portion defining an inside cylindrical sur formed along a direction of disassembly .
face that is substantially coextensive with the small
diameter cylindrical portion ;