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Abstract

A spark plug and method for making. The spark plug comprises a center electrode, an insulator surrounding the center electrode, and a metallic shell surrounding the insulator. The spark plug also includes a ground electrode engaged with the metallic shell. The ground electrode has a first surface facing the center electrode for defining a spark gap and a second surface opposite the first surface. A cross-section of the ground electrode between the first and second surfaces includes a first zone of a non-noble metallic base material extending a distance from the second surface toward the first surface and a second zone of a blend of the non-noble base material and a noble metallic material extending from the first zone to the first surface. A method of making the spark plug includes the step of disposing a quantity of noble metallic material on an electrode blank formed of a non-noble metallic base material. The method also includes the step of at least partially melting the quantity of noble metal with a beam emitted by a laser. The method also includes the step of sequentially moving the laser along the electrode blank in first and second opposite directions to enhance the distribution of the molten quantity of noble metal over the electrode blank.

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First Claim