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who knows in detail the process of casting a cylinder head?

Discussion in 'The Hokey Ass Message Board' started by Manche, Feb 7, 2011.

  1. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    As title says, one with water jacket and oil passages.
     
  2. 38FLATTIE
    Joined: Oct 26, 2008
    Posts: 4,349

    38FLATTIE
    Member
    from Colorado

    Manche, I going to have to follow this one! I'd like to hear a good answer.:D
     
  3. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    So do I, nothing I found today has been satisfactory so far.
     
  4. RodStRace
    Joined: Dec 7, 2007
    Posts: 3,927

    RodStRace
    Member

    That's kind of like asking how to TIG stainless steel sheet. There is a lot of general info and special steps to learn before you jump into a casting with water passages, chambers and such.
    There are some great casting tech threads here, and a guy that machined his own cylinder head. Read up on those.
     

  5. 57tailgater
    Joined: Nov 22, 2008
    Posts: 845

    57tailgater
    Member
    from Georgia

    You're going to need some big info on creating cores to create the passages. I bet you can find plenty of schtuff on the web to get you started. :cool:
     
  6. 38FLATTIE
    Joined: Oct 26, 2008
    Posts: 4,349

    38FLATTIE
    Member
    from Colorado

    Manche, contact Garen Phillips-Dzuari here on the board. He has a foundry, and does this for a living.
     
  7. RichFox
    Joined: Dec 3, 2006
    Posts: 10,020

    RichFox
    Member Emeritus

    Don Ferguson, (Paramount Forge) casts Ardun heads. Nic Aries makes the Aries/Howard head. Joe Fontana makes Skinner heads and some different blocks. They might be good guys to inquire of.
     
  8. Dale Fairfax
    Joined: Jan 10, 2006
    Posts: 2,585

    Dale Fairfax
    Member Emeritus

    Start with some books on Foundry Practice and Pattern Making. Most heads are cast in a sand mold which is destroyed after the casting is solidified. The sand mold was created by ramming sand around a pattern which represents the exterior of the head. When the pattern is removed from the sand, baked sand cores representing all of the interior passages (water jacket, intake and exhausr ports) is carefully placed into the cavity in the sand (left when the pattern was removed). When the hot metal is poured into the mold it surrounds and encapsulates the cores while filling out the extrior shape left by the pattern.




     
  9. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    and how do you remove the passage material to make it hollow as it should be?
     
  10. HotRodBen1987
    Joined: Jul 29, 2009
    Posts: 691

    HotRodBen1987
    BANNED

    Good info. Core and pattern making is an art with many unforseen problems that can occur if you don't get it right. You will have to think about draft, parting line, gates, runners, sprues, type of sand to use depending on material casting, etc. so that it all pulls apart well and there is no porosity, breakout, cold fill, poor finishes, etc. Too much to explain on here for sure
     
  11. chaos10meter
    Joined: Feb 21, 2007
    Posts: 2,191

    chaos10meter
    Member
    from PA.


    Thats' what the cores do make the internal passages, most of the spent core sand will generally fall out once poured, no bake sands are a bit harder to get out but with some vibration and a little poking around, then blasting it will come out.
     
  12. The whole process starts with a wooden mold. Both positive and negative molds. Those molds are used to create impressions or replicas of the shape in sand. Special casting sand with binders and formed under pressure. The negative portion of the mold gets filled with metal leaving a positive metal placement, the positive portion of the sand mold creates a void or negative metal placement and when removed leave the open passage.
     
  13. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    I was well aware of sand molding. I suppose they place a net of rods and other stuff to make the passages and then its removed right?
     
  14. RichFox
    Joined: Dec 3, 2006
    Posts: 10,020

    RichFox
    Member Emeritus

    The sand goes where there will be a space (Water jacket, port) in the finished product. Sometimes wire is used to help hold the sand togeather. After casting the sand is broken apart and dumped out. Oil passages and smaller type stuff like that are drilled in the casting.
     
  15. If you saw the modern process to make an aluminum high pressure die cast cylinder head you would be amazed at how ancient and barbaric the process is. It's automated now but unchanged.
    The passage sand cores are absolutely amazing to look at. The head that pops out of the die needs a lot of machine work and is barely recognizable until it gets trimmed.
     
  16. wingedexpress
    Joined: Dec 24, 2006
    Posts: 893

    wingedexpress

    dolmetsch(sp) thread on making pistons has a good overview of making a simple inner core for the pistons.It is basically the same idea but you will have two separate cores one for the water and one for the air/fuel mix.Alignment of the cores would be critical.
     
  17. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    So if a wax mold is an exact copy of a head minus the oil passages, how to the foundry workers manage to make such intricate holes?
     
  18. chaos10meter
    Joined: Feb 21, 2007
    Posts: 2,191

    chaos10meter
    Member
    from PA.


    You can use wire or rods depending on the core sand material and if the core needs it for strength.
    Usually have to vent them also to let the gas out.
     
  19. Its not the foundry workers, its the guys in the mold and pattern shop. Highly skilled extremely anal carpenters that specialize in carving the molds. Very few individuals on the planet are capable of this work and only a few are needed to mass produce any cast part.

    The molds are true works of art
     
  20. Dale Fairfax
    Joined: Jan 10, 2006
    Posts: 2,585

    Dale Fairfax
    Member Emeritus

    Just the way I told you. The foundry workers make those intricate holes by placing the sand cores in the mold. When the casting cools, the cores have to broken up so they will fall out-leaving the voids (ports & waterjacket) behind. Sometimes there are wires inserted in the mold and into the cores to hold them in place when the molten metal rushed into the cavity.




     
  21. 19Fordy
    Joined: May 17, 2003
    Posts: 8,025

    19Fordy
    Member

    So true re: core wires. I found one inside my 8BA block that had never been removed at the foundry.
     
  22. RichFox
    Joined: Dec 3, 2006
    Posts: 10,020

    RichFox
    Member Emeritus

    The only sand core that remains in the casting is the water jacket. It needs to be broken up and vibrated out casting holes.The ports are open on both ends and easily knocked out. Head bolt holes, oil passages, valve guides, sometimes pushrod holes and all that stuff is cast solid and machined into the casting. Which intricate holes is it you are asking about?
     
  23. chaos10meter
    Joined: Feb 21, 2007
    Posts: 2,191

    chaos10meter
    Member
    from PA.


    That is actually what we call a shell core, a plastic resin sand that is usually made in a cast iron heated core box and the sand activated by heat usually 400 to 500 degrees. There is also cold box shell.
    If you ever have a cold or clogged up head take a good whiff of a fresh, hot shell core, it will open your head up in a nano second.
    Probably not good for you so I won't tell you about x-raying guys that over exercised on the weekend or think they hurt themselves with one of smallest X-Ray machines the quarter million machine, 250K volts !
    We stopped that shit when we shot a guys head cause he had a stiff neck and the dumb prick took the film to his doctor./

    Ahhh the good old foundry days.
     
  24. mikeey rat
    Joined: Aug 10, 2010
    Posts: 169

    mikeey rat
    Member
    from Australia

    GUYS check out an article in Australian street machine called ;A NEW HEAD ON THE BLOCK ; Its about casting 6cyl hemi head thatis on australias fastest naturally aspirated street car
     
  25. mikeey rat
    Joined: Aug 10, 2010
    Posts: 169

    mikeey rat
    Member
    from Australia

    seriously guys it is agood article and probably of real interest to the inline 6 chrysler guys it goes through the whole process with some great pics
     
  26. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    perhaps if you leave a link?
     
  27. mikeey rat
    Joined: Aug 10, 2010
    Posts: 169

    mikeey rat
    Member
    from Australia

    Im not really computer litterate but i did a post to inline mopar guys and another hamber put the link in their reply once you get on the cylinder head innovation site go to the article section . the article is called A NEW HEAD ON THE BLOCK H ope this article helps you
     
  28. RobsHemiA
    Joined: Jan 25, 2007
    Posts: 110

    RobsHemiA
    ALLIANCE MEMBER

  29. Manche
    Joined: Dec 11, 2010
    Posts: 111

    Manche
    Member

    That explains it, Thank you very-farting-much!

    Now is time to think which flatheads never had an OHV kit to it............
     

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