Casting methods with composite molded core assembly

Abstract

A core assembly is formed by fabricating a first core, molding a destructible plastic layer around the first core, and molding a second core around the plastic layer. The plastic layer is interlocked .[.wth.]. .Iadd.with .Iaddend.an irregular outer surface of the first core, and the second core is interlocked with an irregular outer surface of the plastic layer. The core assembly can be used for casting engine cylinder heads to eliminate the need for gluing cores together and the accompanying formation of fins within fluid conducting passages.

I claim: 
     
       1. A method of casting metal castings comprising the steps of: forming a composite core assembly by: fabricating a first core having an irregular outer surface portion;   molding a destructible layer of cellular plastic material around said irregular outer surface portion of said first core, such that an inner surface of said layer intimately contacts and conforms to the configuration of said irregular outer surface portion of said first core to interlock said first core and said plastic layer together, and such that the outer surface of said plastic layer includes an irregular surface portion; and   molding a second core in encompassing relation around said irregular outer surface portion of said plastic layer, such that an inner surface of said second core intimately contacts and conforms to the configuration of the irregular outer surface portion of said plastic layer to interlock said second core and said plastic layer together, and such that the outer surface of said second core is of nonconforming shape relative to the outer surface of said plastic layer;     forming a mold cavity within a pair of mold halves; inserting said core assembly as an integral unit within one of said mold halves;   securing said mold halves together; and   introducing molten metal into said cavity to destroy said plastic layer and form said casting.   
     
     
       2. A method according to claim 1 wherein said step of molding a destructible layer comprises inserting said first core into a corebox, applying thermoplastic resinous pellets around said first core and expanding said pellets around said first core. 
     
     
       3. A method according to claim 2 wherein said step of applying resinous pellets comprises applying pre-expanded polystyrene pellets. 
     
     
       4. A method of forming a core assembly comprising the steps of: fabricating a first core having an irregular outer surface portion;   inserting said first core in to a first mold and molding a destructible layer of cellular plastic material in encompassing relation around said irregular outer surface portion of said first core such that an inner surface of said plastic layer intimately contacts and conforms to the configuration of said irregular outer surface portion of said first core to interlock said first core and said plastic layer together, and such that the outer surface of said plastic layer includes an irregular surface portion; and   inserting as a unit said first core and said molded plastic layer into a second corebox having a cavity which defines a surface of nonconforming shape relative to the outer surface of said plastic layer, and molding a second core in encompassing relation around said irregular outer surface portion of said plastic layer such that an inner surface of said second core intimately contacts and conforms to the configuration of the irregular outer surface portion of said plastic layer to interlock said second core and said plastic layer together.   
     
     
       5. A method according to claim 4 wherein said step of molding a destructible layer comprises inserting said first core into a corebox, applying thermoplastic resinous pellets around said first core and expanding said pellets around said first core. 
     
     
       6. A method according to claim 5 wherein said step of applying resinous pellets comprises applying pre-expanded polystyrene pellets. 
     
     
       7. A coring assembly for use in casting a cylinder head for an internal combustion engine, comprising: a port core having a base and port-defining extensions projecting generally laterally and downwardly from said base in generally parallel relationship; said port-defining extensions having irregular outer surface portions;   said base and port-defining extensions terminating downwardly in essentially coplanar positioning members;     a molded-in-place destructible layer of cellular plastic material disposed in encompassing relation around a substantial portion of said port-defining extensions of said port core; said plastic layer including a plurality of spaced upstanding posts for forming cast-in-place valve guide bosses of the engine and forming an irregular outer surface portion of said plastic layer; said plastic layer including an inner surface which intimately contacts and conforms to the irregular outer surface portion of said port core to interlock said port core and said plastic layer together;     a molded-in-place cooling jacket core disposed in encompassing relation around a substantial portion of said plastic layer including said upstanding posts; said cooling jacket core terminating downwardly in a positioning portion and including an inner surface which intimately contacts and conforms to the irregular outer surface portion of said plastic layer to interlock said cooling jacket core and said plastic layer together, the outer surface of said cooling jacket core being of nonconforming shape relative to the outer surface of said plastic layer.     
     
     
       8. A core assembly according to claim 7 wherein said destructible layer comprises a thermoplastic resinous material. 
     
     
       9. A core assembly according to claim 8 wherein said thermoplastic resinous material is polystyrene. .Iadd.10. A method of casting metal castings comprising the steps of: fabricating a composite core assembly by molding a destructible layer of cellular plastic material such that a surface of said plastic layer includes an irregular surface portion; and   forming a core in encompassing relation around said irregular surface portion of said plastic layer by blowing a mixture of sand and binder around said surface portion, such that a surface of said core intimately contacts and conforms to the configuration of the irregular surface portion of said plastic layer to interlock said core and said plastic layer together;     forming a mold cavity within a pair of mold sections;   inserting said core assembly as an integral unit within one of said mold sections;   securing said mold sections together; and   introducing molten metal into said cavity to destroy said plastic layer and   
     
     
        form said casting..Iaddend..Iadd. 11.  A method according to claim 10, wherein said step of molding a plastic layer comprises fabricating an initial core having an irregular surface portion, inserting said initial core into a corebox, applying thermoplastic resinous pellets around said initial core, and expanding said pellets around said initial core such that a surface of said plastic layer intimately contacts and conforms to said irregular surface portion of said initial core..Iaddend..Iadd. 12. A method according to claim 11, wherein said step of applying resinous pellets comprises applying pre-expanded polystyrene pellets. .Iaddend. .Iadd. 13. A core assembly for use in metal casting operations, comprising: a first core having an irregular outer surface,   a mold-in-place, destructible layer of plastic cellular material disposed around at least a portion of said outer surface of said first core, with an inner surface of said plastic layer intimately contacting and conforming to the irregular configuration of said first core to interlock said first core and plastic layer such that removal of said plastic layer from said first core in any direction is prevented; said first core and said plastic layer forming a composite core subassembly; and     a formed-in-place second core encompassing a portion but not all of said subassembly in overlying relation to said plastic layer and in non-engagement with said first core; an inner surface of said second core intimately contacting and conforming to an irregular surface portion of said plastic layer to interlock said second core and said plastic layer..Iaddend. .Iadd. 14. A core assembly according to claim 13, wherein said second core comprises sand and binder. .Iaddend..Iadd. 15. A core assembly according to claim 13, wherein said plastic layer comprises a thermoplastic resinous layer..Iaddend..Iadd. 16. A core assembly according to claim 15, wherein said resinous material is polystyrene.