Need to repair cylinder bore ID on alloy block

Posted by Erik Berg ( on 02:43:50 12/11/05

I have an alloy Cosworth BD engine block that had a wrist pin let go during a race. The piston dragged the liner violently up and down in the bore, gouging it rather badly. California Cosworth expert Steve Jennings extracted the dead iron liner, then had an expert technician do some TIG build-up inside the damaged bore, but aborted the job because he felt too much added material (and too high temperature, potentially compromising the heat treat) would be required to finish.
What I want to find is a coating material and process capable of 3~4 mm of material buildup, good adhesion to the high Silicon Aluminum casting alloy, reasonably high tensile strength, and that will not raise the temperature of the base metal too much, so that the heat treat of the base material will not be affected.
Understand here that I do not need a high wear surface finish as used on linerless Aluminum engines; this bore is going to receive a standard dry spin-cast iron liner again after the ALuminum base metal is repaired to its original (or close) bore diameter.
Any ideas?
Erik Berg
Southern California

Follow Ups:
Surface Engineering Forum

Surface Engineering Message Board Archive

Surface Engineering Message Board Archive Index

Post A Message!

Gordon England Surface Engineering ForumPlease go to the new Surface Engineering Forum as this old message board is a read only archive. Please copy and paste relevant information or link to the page if you wish to reactivate a thread on the new forum.

Gordon England Independent Thermal Spray Coating Consultant
Telephone: +44 (0)1252 405186


Site Links


Nature of Thermal Spray Coatings

Surface Engineering in a Nutshell

Surface Engineering Forum

Thermal Spray Gun Repair Service

Plasma Consumable Parts

Thermal Spray Powder Supplies


Thermal Spray Coatings on Carbon and Glass Fibre Reinforced Polymers

HVOF Coating of Paper Making Roll

Abradable Coatings


Thermal Spray Processes:

Combustion Wire Thermal Spray Process

Combustion Powder Thermal Spray Process

Arc Wire Thermal Spray Process

Plasma Thermal Spray Process

HVOF Thermal Spray Process

HVAF Thermal Spray Process

Detonation Thermal Spray Process

Plasma Flame Theory

Cold Spray Coating Process

Wear and Use of Thermal Spray Coatings

Corrosion and Use of Thermal Spray Coatings

Glossary of Thermal Spray and Surface Engineering Terms

Image Directory for Thermal Spray Coatings

Plasma Gas Flow Information

Plasma Gas Flow Correction Calculator

Contact Form

Links to other interesting sites related to thermal spray and surface engineering

Reciprocal Links

Periodic Table of the Elements

SI Units

Calculators for Conversion between Units of Measurement

Hardness Testing

Surface Engineering Message Board Archive

Surface Engineering Message Board Archive Index

Photography Gallery2

Photography Gallery3

© Copyright Gordon England