Abstract: A method for casting metals around an article having a bore extending along a central axis and defined at least in part by an interior cylindrical wall portion utilizes a mandrel having a cylindrical exterior surface portion sized to be slidingly positioned in said bore in close relationship with said interior cylindrical wall portion. The mandrel has an annular groove in which is positioned a canted coil spring with a series of outer contact points extending radially outwardly beyond said cylindrical exterior surface portion. The article is moved onto the mandrel to compress the spring and deflect the outer contact points such that the spring imparts an outwardly directed force to the article interior cylindrical wall portion to provide frictional resistance between the spring, outer contact points and the interior cylindrical wall portion to retain the article on the mandrel while casting molten metal around the mandrel supported article to form a cast part.

Abstract: A stationary die for a horizontal die casting machine has an oscillatable molten metal injector below the die that oscillates from an acute angle outside the die for filling with molten metal to an acute angle under the die or injecting the molten metal into the die. The stationary die has an annular docking block at the same acute angle to the horizontal as the axis of the shot sleeve under the die. The edge of the aperture at the outer end of the docking block is adjacent to and substantially in the plane of the parting surface of the stationary die so that the docking block per se projects outwardly from the surface. Correspondingly, the adjacent parting surface of the movable die is provided with a cavity for fitting this projection of the docking block, but since the surfaces of this docking block are at convergent acute angles, they provide no restriction to the movement of the movable die.

Abstract: This disclosure concerns a casting die for a cylinder, including engine blocks having a plurality of cylinders such as for internal combustion engines, including an expendable core for forming a jacket around the cylinders. This core has a printout portion at one end of the cylinder which is held in place by a cooperating flange on a mandrel that fits inside the cylinder. This mandrel may hold a liner for the cylinder. A dowel is provided in one of the die parts for insertion into the hollow mandrel. The mandrel is held in position by being clamped between the two opposing die parts, and the flanges of the core printout portion may be loosely held in the printout cavity of one of the die parts which preferably also contains one or more locating pins for bridging at least part of the gap between the printout portion and the printout cavity in the die for better positioning the core in the die.

Abstract: The hollow frusto-conical expendable core is used for forming a jacket around a cylinder in a casting die for forming a cylinder block. The core has a printout portion comprising an inwardly extending annular flange connected to the narrower end of the frusto-cone by circumferentially spaced axially extending legs. The core may comprise a plurality of frusto-cones for a corresponding plurality of cylinders in an engine block with their axes parallel in a common plane with the annular flanges of their printout portions integrally connected for strengthening the multi-cylinder jacket core.

Abstract: The locating pins have notched ends, each of which simultaneously restricts the movement of an expendable core in two orthogonal directions in a die casting die. A plurality of these pins alone and with other pins project into the space between the printout cavity in a die casting die and the printout portion of an expendable core positioned in that cavity. Other pins having flat ends locate the core in only one directional line. Still other pins having tapered ends require special pockets in the printout section of the core, which pockets have sides that must be formed adjacent to the tapered surfaces of these pins. The configurations of the space around the printout portions of the cores permit molten metal injected into the die to produce a skin or skull over the printout portions, which skin can have thicker ribs or portions through it for further reinforcing the printout portions.