A method for casting an iron alloy reinforced aluminum alloy engine block
AssigneeFord Global Technologies, LLC
InventorStaffan Rengmyr
Life of this patent
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Abstract
Abstract of Disclosure A method of high pressure die casting in iron alloy reinforcements for main bearing scantlings in an aluminum alloy engine block for an internal combustion engine. Prior to casting, reinforcements (1) having bores (6) for main bearing screws are placed in a die cavity (21), so that cores for main bearing screws protrude into the bores in each reinforcement on one side of the reinforcement. Then the reinforcements are fixed in the die cavity by placing a cylinder liner core (25) against a surface (27) of the reinforcement on the opposite side of the reinforcement.
Claims13
A method of high pressure die casting in first metal alloy reinforcements for main bearings scantlings in a second metal alloy engine block for an internal combustion engine, comprising the following steps:
- placing a first metal alloy reinforcement having bores for main bearing screws and an essentially semi-circular surface facing the main bearings between said bores at each scantling location in a die cavity, so that first core means in the die cavity protrude into said bores on one side of the reinforcement;
- fixing the reinforcement in the die cavity by placing second core means in the die cavity against a surface of the reinforcement on the opposite side;
- and
- introducing and pressurizing a molten second metal alloy in the die cavity.
A method according to claim 1, wherein the reinforcement is placed in the die cavity, so that cores for main bearing screw bores protrude into the bores in the reinforcement on said one side of the reinforcement.
A method according to claim 1, wherein the reinforcement is fixed in the die cavity by placing a cylinder liner core against the surface of the reinforcement on said opposite side.
A method according to claim 1, wherein reinforcements made of an aluminum alloy are placed in the die cavity and that a molten aluminum alloy is thereafter introduced and pressurized in the die cavity.
A method of high pressure die casting in first metal alloy reinforcements for main bearing scantlings in a second metal alloy engine block for an internal combustion engine, comprising the following steps:
- placing a first metal reinforcement having bores for main bearing screws and an essentially semi-circular surface facing the main bearings between said bores at each scantling location in a die cavity, so that cores for main bearing screw bores in the die cavity protrude into said bores on one side of the reinforcement;
- fixing the reinforcement in the die cavity by placing a cylinder liner core against the surface of the reinforcement on the opposite side;
- and
- introducing and pressurizing a molten second metal alloy in the die cavity.
A method according to claim 5, wherein reinforcements made of an iron alloy are placed in the die cavity and that a molten aluminum alloy is thereafter introduced and pressurized in the cavity.
A metal alloy block for an internal combustion engine, comprising a plurality of cylinder bores, scantling means for main bearings between adjoining cylinder bores, a scantling reinforcement made of a metal alloy different from said metal alloy of the block and having an essentially semi-circular surface facing said main bearing incorporated in each scantling means and bores for main bearing screws in said reinforcement, wherein the maximum width of said reinforcement in the axial direction of the engine block is larger than the minimum thickness of the cylinder wall between adjoining cylinder bores.
Engine block according to claim 5, wherein an outer peripheral surface of said reinforcement has a flat central area.
Engine block according to claim 5, wherein depressions are formed in opposite peripheral surfaces of the reinforcement.
Engine block according to claim 7, wherein said reinforcement has at least one through-channel in a portion between said bores, said through-channel and said depressions being filled with the same alloy as and alloy forming a coherent mass with the surrounding metal alloy of the block.
Engine block according to claim 5, wherein the engine block is made of an aluminum alloy and the reinforcements of an iron alloy.
A metal alloy block for an internal combustion engine, comprising a plurality of cylinder bores, scantling means for main bearings between adjoining cylinder bores, a scantling reinforcement made of a metal alloy different from the metal alloy of the block and having an essentially semi-circular surface facing said main bearing incorporated in each scantling means, bores for main bearing screws in said reinforcement, the maximum width of said reinforcement in the axial direction of the engine block being larger than the minimum thickness of the cylinder wall between adjoining cylinder bores, a flat central area on an outer peripheral surface of said reinforcement, at least one through-channel in a portion of the reinforcement between said bores and depressions formed in opposite peripheral surfaces of the reinforcement, said through-channel and said depression being filled with a metal alloy forming a coherent mass with surrounding metal alloy material.
Engine block according to claim 10, wherein the engine block is made of an aluminum alloy and the reinforcements of an iron alloy.