Production of integrated automotive part in high pressure diecasting process using salt core

Abstract

A new concept of salt core, a melting temperature of which is lower than the solidus temperature of cast alloy I was introduced to produce an integrated casting part having a complicated inner shape or requiring under-cut in high pressure die casting or squeeze casting process. A salt core, named a fusible core in this paper because the salt core can be easily extracted just as holding at a temperature under a solidus temperature of a casting alloy, was developed and applied to produce a fuel control part for automotive GDI engine in high pressure diecasting machine. A different salt material of a lower melting temperature than that of Al alloy was mixed with a different ceramic particulate to improve a thermo-physical. property of fusible core. The thermo-physical property of the fusible core was measured and a weight faction of the ceramic particulate was optimized. The selected core materials were poured in metallic mold by gravity to produce a fusible core for a fuel control part for automotive GDI engine. The fuel control part, which the fusible core was included inside, was successful to fabricate in a conventional diecasting machine with no melting of fusible core during casting.