Importance

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Abstract

Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.

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First Claim