Manufacturing – Casting methods - European Aluminium Association

1.4.3 Process description – Core manufacturing
See also:
AAM – Applications – 1 Power train > Engine > Cylinder block
This process applies entirely resin bonded sand cores. Specifically, silica sand is used in the
polyurethane cold-box process. The core package comprises also the whole running and
feeding system. The core packages are, to a large extent, assembled automatically.
Production lines with a capacity of up to 160 core packages per hour are currently in
operation.
Extremely tight tolerances are achievable, so that e.g. grey iron liners can be placed into the
core package with a position tolerance of +-0.3 mm.
Usually, the core packages are stored in a buffer and then fed into the casting line.
Inserted parts such as grey iron liners can be preheated by induction coils in their final
position in the core package prior to mould filling. This guarantees reproducible and
repeatable conditions concerning the contact between the grey iron liners and the aluminium
cast alloy.
Fully automatic core package assembly with robots
Source: VAW
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