ALUMINUM CASTING DESIGN WITH ALLOY SET CORES FOR IMPROVED INTERMETALLIC BOND STRENGTH

• Main Authors: MAKI, Clifford E, SCHEPAK, Antony, BOILEAU, James
• Format: Patent
• Language: English
• Published: 17.12.2020
• Subjects: ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES; BLASTING; CASTING; CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES; CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS ANDNON-FERROUS ALLOYS; CHEMISTRY; COMBUSTION ENGINES; CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; FERROUS OR NON-FERROUS ALLOYS; HEATING; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS; LIGHTING; MECHANICAL ENGINEERING; METALLURGY; PERFORMING OPERATIONS; POWDER METALLURGY; TRANSPORTING; TREATMENT OF ALLOYS OR NON-FERROUS METALS; WEAPONS

An engine block formed according to a method that includes forming an insert, coating the insert with a bond material, placing the insert within a casting mold or die, purging the casting mold or die with an inert gas, filling the casting mold or die with molten metal to encapsulate the insert, diffusion bonding the molten metal to the insert to form a diffusion bonded insert, placing the diffusion bonded insert within a cavity of a secondary casting mold or die, filling the secondary casting mold or die with molten metal to form an engine block composite casting assembly, and casting and heat treating the engine block composite casting assembly is provided. The insert can be free of serrations for mechanical coupling between the insert and the engine block.