Manufacturing – Casting methods - European Aluminium Association

1.4.2 Design features
The question, which casting process is optimal for a given product, depends, beside other
factors, on the desired complexity of the casting. Like all precision sand casting processes,
the core package casting process offers almost unlimited possibilities for product design, e.g.
for engine block castings:
Complicated oil galleries and pre-cast oil channels to feed the crankshaft bearings.
Complex exhaust gas return systems.
Secondary air ducts.
1 mm thick cooling water passages between the cylinders (facilitated by micro-core
technology).
Casting-in of cylinder liners.
Hang-on and functional parts, such as thermostat housing, oil filter flange and splash wall can
be integrated into the engine block with the core package process.
Furthermore, the process provides extensive design freedom, for example in the design of
undercuts, to reduce weight through the use of additional cores and/ or cavities and curved
ports.
Different designs for oil gallery cores
Source: VAW
Example of a complex oil gallery core design
Source: VAW
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