Method and apparatus for casting aluminum engine blocks with cooling liquid passage in ultra thin interliner webs

Abstract

Casting method and apparatus for forming fluid cooling passages in the webs having a minimum dimension of 3 mm or less between iron cylinder liners in aluminum engine blocks by utilizing very thin pre-formed reinforced cores inserted between adjacent liners and conjoined with the outer water jacket core. The reinforced core is made of a supportive very thin reinforcing element, preferably in the form of a rectangular metal strip, or other material that withstands the casting process, with a thin coating layer that protects such element and permits its ready removal after formation of the casting, which layer may advantageously and inexpensively be formed of conventional casting sand with a typical binder.

1 . A method of casting an open passage in a cast aluminum product in a narrow web of a width of less than about 3 mm comprising forming a reinforced coated core having at least one support strip with an coating layer effective to prevent adherence of said strip to the cast aluminum, to retain the outer shape of the core during casting, and permitting release of the strip after casting the product, and casting the said product to form said web with said passage.  
   
   
       2 . A method according to  claim 1  for casting an engine block with a water jacket; 
 comprising using sand and binder to form said coating layer and inserting said reinforced sand coated core in the interliner space between the pairs of cylinders of the engine block and positioned to form a fluid cooling passage extending between portions of said water jacket.    
   
   
       3 . A method according to  claim 1  for casting an engine block having iron cylinder liners; wherein the strip is made of a metal that does not melt at the casting temperatures and is of a generally rectangular cross section.  
   
   
       4 . A reinforced sand coated core comprising having a width of less than 3 mm, having a reinforcing support strip and a coating of bonded sand or equivalent.