From Ford:
It's called Plasma Transferred Wire Arc Spray Bore, which we'll shorten to PTWA. This process uses a consumable steel wire like a MIG welder and coats the aluminum cylinder with iron oxide.
Now hold on a second. Isn't iron oxide rust? Yes, but there are different iron oxides separated by crystalline structure. Get the right kind of FeO and you have a very hard, durable finish, according to Ford's manager of materials and manufacturing research Matt Zaluzec.
The coating operation starts with a machine that cuts small, spiral grooves in the cylinder. Next the tip goes down the bore. High-voltage electricity arcs from the steel wire to a ground and a blast of compressed air sprays the plasma on the cylinder walls where the material--when combined with atmospheric oxygen--turns to the right kind of iron oxide.
PTWA is not new--the aerospace industry uses it to toughen aluminum components like turbine blades--but Zaluzec said, "We applied the Henry Ford method," meaning that the company was able to make the technology affordable. Typically PTWA had been done in a vacuum with an expensive consumable wire.
5.8 in 5.0 magazine.
http://www.mustang50magazine.com/te...ord_shelby_gt500_trinity_5_8l_v8/viewall.html