Remanufactured exhaust system component

Abstract

An exhaust system component is disclosed. The exhaust system component may have a tubular body that defines a passage. The tubular body may have a joining portion that is configured to fluidly connect the passage to another exhaust system component. The joining portion may have a first layer of cast iron. The joining portion may also have a second layer covering at least a portion of the first layer. The second layer may contain at least iron, chromium, and aluminum.

What is claimed is: 
     
         1 . An exhaust system component, comprising:
 a tubular body defining a passage and including a joining portion configured to fluidly connect the passage to another exhaust system component,   wherein the joining portion includes:
 a first layer of cast iron; and 
 a second layer covering at least a portion of the first layer and containing at least iron, chromium, and aluminum. 
   
     
     
         2 . The exhaust system component of  claim 1 , wherein the joining portion defines an open end of the tubular body. 
     
     
         3 . The exhaust system component of  claim 2 , wherein the joining portion extends from the open end to a material intersection, the material intersection being a location where an exposed surface of the second layer is continuous with an exposed surface of the first layer. 
     
     
         4 . The exhaust system component of  claim 1 , wherein the second layer is mechanically bonded to an outer surface of the first layer. 
     
     
         5 . The exhaust system component of  claim 1 , wherein the second layer is mechanically bonded to an inner surface of the first layer. 
     
     
         6 . The exhaust system component of  claim 1 , wherein the second layer contains approximately 65-80% iron, 15-30% chromium, and 3-6% aluminum. 
     
     
         7 . The exhaust system component of  claim 1 , wherein the second layer has a thickness of approximately 0.1-2.0 mm. 
     
     
         8 . The exhaust system component of  claim 1 , wherein the tubular body is configured to be mounted to an engine and the passage is configured to receive exhaust gas from a combustion chamber of the engine. 
     
     
         9 . A method of remanufacturing an exhaust system component having a cast iron tubular body that defines a passage and includes a joining portion configured to fluidly connect the passage to another exhaust system component, the method comprising:
 removing material from the joining portion; and   depositing a coating material on the component at a location where the material was removed,   wherein the coating material contains at least iron, chromium, and aluminum.   
     
     
         10 . The method of  claim 9 , wherein the coating material is deposited using a wire arc spray process. 
     
     
         11  The method of  claim 9 , wherein removing the material from the joining portion includes removing the material from an outer surface of the tubular body. 
     
     
         12 . The method of  claim 9 , wherein removing the material from the joining portion includes removing the material from an inner surface of the tubular body. 
     
     
         13 . The method of  claim 9 , further including removing a portion of the coating material to achieve a working thickness of the tubular body. 
     
     
         14 . The method of  claim 9 , wherein the exhaust component is a section of an exhaust manifold and the method further comprises disassembling the exhaust manifold before removing the material and reassembling the exhaust manifold after depositing the coating material. 
     
     
         15 . The method of  claim 14 , Wherein reassembling the exhaust manifold includes inserting the joining portion into a portion of another section of the exhaust manifold or receiving a portion of another section of the exhaust manifold in the joining portion. 
     
     
         16 . The method of  claim 9 , wherein the coating material contains approximately 65-80% iron, 15-30% chromium, and 3-6% aluminum. 
     
     
         17 . The method of  claim 9 , wherein removing the material includes removing approximately 0.1-2.0 mm of cast iron material from a thickness of the tubular body and depositing the coating material includes adding approximately 0.5-3.0 mm of coating material to a thickness of the tubular body. 
     
     
         18 . An exhaust manifold, comprising:
 a first manifold section defining a first passage and including a first joining portion; and   a second manifold section defining a second passage and including a second joining portion,   wherein the first joining portion is received within the second joining portion at a joint of the exhaust manifold, and   wherein at least one of the first joining portion and the second joining portion includes:
 a first layer of cast iron; and 
 a second layer covering at least a portion of the first layer and containing at least iron, chromium, and aluminum. 
   
     
     
         19 . The exhaust manifold of  claim 18 , wherein only one of the first joining portion and the second joining portion include the second layer. 
     
     
         20 . The exhaust manifold of  claim 18 , wherein both of the first joining portion and the second joining portion include the second layer.