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Thread: Air Cooled Cylinder Head Shell Casting

  1. #1
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    Air Cooled Cylinder Head Shell Casting

    Not long ago, we made some cylinder heads for a 2 stroke engine that we're developing.

    We decided to use a resin coated sand shell for pouring the cylinder heads. Mainly because we'd never tried this technique before.


    Here are some videos of the process;








    Some photos of the pattern and sand box;

    molds and sand reservoir.jpg

    molds and sand reservoir 2.jpg

    The molds that we made using the patterns;

    sand molds.jpg

    sand mold 2.jpg

    The resulting castings;

    cylinder head casting.jpg

    cylinder head casting2.jpg

    After machining...

    cylinder head machined.jpg

    and mounted on the engine;

    cylinder head on the engine.jpg

    cylinder head on engine 2.jpg

  2. #2
    Senior Member TRYPHON974's Avatar
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    That's a nice work!
    Jack of all trades, master of none.
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  3. #3
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    Impressive, thanks for sharing.
    That was a lot of pattern work, could you explain the need for the horizontal vents?
    Bones

  4. #4
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    After you finish pouring, gasses from the burning resin bubble through the still molten metal causing gas entrapment defects. The vents offer a low resistance path for the gasses to escape

  5. #5
    Senior Member TRYPHON974's Avatar
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    I forgot to ask but what is the powder you sprinkle when you just poured? Is it gunpowder?
    Jack of all trades, master of none.
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  6. #6
    Quote Originally Posted by TRYPHON974 View Post
    I forgot to ask but what is the powder you sprinkle when you just poured? Is it gunpowder?
    That was an exothermic hot topping of some type, it helps make sure the riser is the last thing to solidify thus helping to reduce shrinkage defects. If you're interested, you can read more about hot toppings HERE:

  7. #7
    Senior Member TRYPHON974's Avatar
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    Quote Originally Posted by rocco View Post
    That was an exothermic hot topping of some type, it helps make sure the riser is the last thing to solidify thus helping to reduce shrinkage defects. If you're interested, you can read more about hot toppings HERE:
    Thanks for the explanation, very interesting.
    Jack of all trades, master of none.
    http://fournaisedupiton.blogspot.com/

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