Lost foam casting of dual alloy engine block

Details Lost foam casting of dual alloy engine block Lost foam casting of dual alloy engine block

1989-12-04

1991-03-19

Seidel, Richard K.

Metal founding

Process

Shaping a forming surface

164 91, 164 95, 164 96, B22C 904, B22D 1916

Patent

active

050002449

ABSTRACT:
In a preferred embodiment, a compound aluminium alloy engine block casting comprises at least a piston-travel region of a cylinder wall section formed of a first alloy, preferably hypereutectic aluminum-silicon alloy, and a remainder including a crankcase section and a water jacket wall formed of a distinct second alloy, preferably hypoeutectic aluminum-silicon alloy. The engine block casting is made by a lost foam process that employs an expendable pattern formed of expanded polystyrene or the like. The pattern comprises a first runner system for casting the first alloy to decompose and replace a portion of the pattern corresponding to the piston-travel region of the casting, and a second runner system for casting the second alloy to decompose and replace the remainder of the pattern. The first alloy and the second alloy are independently but concurrently cast into a singular mold, such that the entire pattern is duplicated, whereupon the alloys merge and fuse to form an integral casting. The preferred product engine block casting advantageously combines the high wear resistance of the hypereutectic aluminum alloy in the cylinder wall section and the reduced porosity and improved machinability of the hypoeutectic alloy throughout the balance of the casting.

REFERENCES:
patent: 3861454 (1975-01-01), Mezey
patent: 4197899 (1980-04-01), Ernest
patent: 4243093 (1981-01-01), Nieman

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