Abstract: Congruent melting salt alloys for use as salt cores in high pressure die casting of metallic alloys for the production of complex metallic parts. Congruent melting salt alloys provide mechanical advantages in the high pressure die casting of both aluminum and magnesium alloys. Salt cores may be used to make complex high pressure die casting parts such as internal passages in a closed deck engine block. The congruently melting salt alloy is cast into a shape of a desired salt core. The cast salt core of the congruently melting slat alloy is placed into a high pressure die casting mold for a complex object. Molten metal is introduced into the high pressure die casting mold to form the complex part. The congruently melting salt alloys may be readily removed from the final cast part through flushing with a solvent, such as water, or through other processes known in the art.

Abstract: Congruent melting salt alloys for use as salt cores in high pressure die casting of metallic alloys for the production of complex metallic parts. Congruent melting salt alloys provide mechanical advantages in the high pressure die casting of both aluminum and magnesium alloys. Salt cores may be used to make complex high pressure die casting parts such as internal passages in a closed deck engine block. The congruently melting salt alloy is cast into a shape of a desired salt core. The cast salt core of the congruently melting slat alloy is placed into a high pressure die casting mold for a complex object. Molten metal is introduced into the high pressure die casting mold to form the complex part. The congruently melting salt alloys may be readily removed from the final cast part through flushing with a solvent, such as water, or through other processes known in the art.

Abstract: A method for the high pressure die casting of an engine block assembly having at least one cast in place cylinder bore in the engine block and a closed head deck surface, and the resultant engine block are disclosed. This closed deck high pressure die cast engine block assembly will preferably have at least two cast in place cylinder bores in the engine block formed by using a composite core of salt core material supported by at least one cylinder bore to be cast in place. The cylinder bores have a lower outer surface preferably defining at least one surface area that interfaces with the engine block during casting such that the at least one cylinder is cast in place in the engine block. An engine block water jacket—as defined by the salt core portion of the composite core—will preferably provide an open passage between each cylinder bore such that water may flow around and entire outer circumference of the upper outer surface of the cylinder bores.