Profile chill for forming a cast device

Abstract

A mold package for forming a cast device such as an engine block is described. The mold package includes a profiled chill and a mold core assembly that is disposed on the profiled chill. The mold core assembly defines a plurality of bulkheads of the engine block. The profiled chill includes a first chill portion having a second chill portion and a plurality of third chill portions arranged thereon, wherein the second chill portion is a semicylindrical element. The third chill portions are arranged to be adjacent to the plurality of bulkheads of the engine block.

Description

INTRODUCTION[0001]In a sand casting process, an expendable mold package is assembled from a plurality of resin-bonded sand cores that define internal and external surfaces of a device, wherein each of the sand cores may be formed by blowing resin-coated foundry sand into a core box and curing it therein. One example includes a sand casting process for an internal combustion engine block.[0002]In one embodiment, the mold assembly method involves positioning a base core on a surface and building up or stacking separate mold elements to shape such casting features. When casting an internal combustion engine block, elements may include sides, ends, valleys, water jackets, cam openings, and a crankcase of the cylinder block, with additional cores being present depending on the engine design.[0003]Removal of thermal energy from liquified metal in a mold package is an important consideration in the foundry process. Rapid solidification and cooling of the cast device promotes a fine grain s...

AI Technical Summary

Benefits of technology

The patent describes an improved cooling system for liquified metal in a foundry process. By using a profiled chill, the system helps to refine the microstructure of the cast aluminum by reducing dendrite arm spacing (DAS) and porosity. This results in stronger, more reliable cast devices that can withstand higher stresses. The system also increases casting efficiency and accuracy.

Problems solved by technology

Excess dendrite lengths, orientations, and configurations may negatively affect tensile strength and fatigue strength, thus affecting the service life of the cast device.

Achieving smaller DAS (Dendrite arm spacing) in a sand cast block may be challenging in certain locations, such as near vent windows and cam bore regions of an engine block.

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