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Lost-foam Casting of dual alloy engine block
Lost-foam Casting of dual alloy engine block
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机译：双合金发动机缸体的消失模铸造
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摘要
In a preferred embodiment of the invention, a process is disclosed for producing a compound aluminium alloy engine block casting (10) which comprises at least a piston-travel region (26) of a cylinder wall section (18) formed of a first alloy, preferably hyper-eutectic aluminium-silicon alloy, and a remainder including a crankcase section (12) and a water jacket wall (20) formed of a distinct second alloy, preferably hypo-eutectic aluminium-silicon alloy. The engine block casting (10) is made by a lost-foam process that employs an expendable pattern (32) formed of expanded polystyrene or the like. The pattern comprises a first runner system (50) for casting the first alloy to decompose and replace a portion of the pattern corresponding to the piston-travel region (26) of the casting, and a second runner system (60) for casting the second alloy to decompose and replace the remainder of the pattern (32). The first alloy and the second alloy are independently but concurrently cast into a single mould (30), such that the entire pattern (32) is duplicated, whereupon the alloys merge and fuse to form an integral casting (10). The preferred product engine block casting (10) advantageously combines the high wear-resistance of the hyper-eutectic aluminium alloy in the cylinder wall section (18) and the reduced porosity and improved machinability of the hypo-eutectic alloy throughout the balance of the casting (10).
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