Restoration process for porosity defects in high pressure die cast engine blocks
AssigneeBrunswick Corporation
InventorsDouglas M. Woehlke, Raymond J. Donahue, Kevin R. Anderson
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Abstract
A restoration process for restoring surface porosity defects in engine blocks cast using a high pressure die cast method. The areas of an engine block having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create an engine block having less than 0.05% surface porosity.
Claims14
A restoration process for repairing surface porosity defects in high pressure die cast engine blocks resulting from the die casting process comprising the steps of:
- identifying an area in a surface containing at least one porosity defect resulting from the die casting process, the area defining a restoration area;
- masking an area adjacent to said restoration area with a mask;
- using a grit blasting process to clean the said restoration area;
- applying a metal spray to said restoration area;
- removing the mask from the area adjacent said restoration area;
- and finishing the restoration area.
A restoration process for repairing surface porosity defects in high pressure die cast engine blocks after machining, the process comprising the steps of:
- identifying areas of restoration in a surface containing surface porosity defects, the defects being a result of the die casting process;
- masking areas in the surface not requiring restoration with a reusable, adhesive backed, rubberized mask, having holes therein corresponding to the areas of restoration;
- placing the masked engine block in a blasting cabinet;
- cleaning the areas of restoration exposed through the mask with an aluminum oxide grit blasting method to remove excess debris in the areas of restoration;
- applying a metal spray to the areas in a surface containing surface porosity defects, wherein the application is done manually with metal spray guns and the spray metal comprises an Aluminum-Silicon alloy having at least 4% Silicon by weight;
- removing the mask from the surface;
- and finishing the surface, wherein the finishing is done manually.
Dependencies are inferred from the claim text.