Abstract: A restoration process for restoring surface porosity defects on a component surface. The areas of a component surface having surface porosity defects are identified for restoration. The restoration surface is subsequently sprayed with a restoration spray to restore the surface porosity defects. The component surface is then finished to create a final component substantially free of surface porosity.

Abstract: A method for manufacturing a connecting rod for an engine contemplates creating a rough connecting rod from high carbon steel. The rough connecting rod is normalized to provide strength and toughness characteristics to the core of the connecting rod for functional operation. A first, second or both ends of the connecting rod are selectively induction hardened to create a durable martensitic structure in those ends. The connecting rod is then cracked and ground to form a final connecting rod for use in internal combustion engines.

Abstract: A restoration process for restoring surface porosity defects resulting from the casting process in metal cast products. The areas of a cast product having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create a cast product having less than 0.05% surface porosity.

Abstract: An aluminum silicon die cast alloy having a very low iron content and relatively high strontium content that prevents soldering to dies into die casting process. The alloys of the present invention also have a modified eutectic silicon and modified iron morphology, when iron is present, resulting in low microporosity and high impact properties. The alloy comprises 6-22% by weight silicon, 0.05 to 0.20% by weight strontium and the balance aluminum. Preferably, the alloy of the present invention contains in weight percent: 6-20% silicon, 0.05-0.10% strontium, 0.40% maximum iron and most preferably 0.20% maximum iron, 4.5% maximum copper, 0.50% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, balance aluminum. On cooling from the solution temperature, the strontium serves to modify the eutectic silicon structure as well as create an iron phase morphology change if iron is present, facilitating feeding through the aluminum interdendritic matrix.

Abstract: A method for the continuous manufacturing of complex cast articles utilizing one or more fluidized beds for heat treatment and aging purposes is herein disclosed. The inventive method contemplates in-line casting, heat treating, quenching, aging and machining of a complex cast aluminum alloy article, such as an engine block or engine block head. Specific advantages of the heat treatment and aging stops of the method of the present invention are herein disclosed.

Abstract: An aluminum-silicon lost foam casting alloy having reduced microporosity and a method for casting the same is herein disclosed. A preferred lost foam cast alloy consists essentially of 6 to 12% by weight silicon and preferably 9.0 to 9.5% by weight silicon, 0.035-0.30% strontium, 0.40% maximum iron, 0.45% maximum copper, 0.49% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, and the balance aluminum. Most preferably, the lost foam alloy is free from iron, titanium and boron. However, such elements may exist at trace levels. Most preferably, the alloy is lost foam cast with the process that applies at least 10 atmospheres of pressure during solidification. However, the range may be 5 to 60 atmospheres. The strontium addition is greater than 0.005% by weight and most preferably greater than 0.05% by weight.

Abstract: A restoration process for restoring surface porosity defects in engine blocks cast using a high pressure die cast method. The areas of an engine block having surface porosity defects are identified and the areas not containing surface porosity defects are masked using an adhesive, reusable, rubberized mask. The masked surface is subsequently cleaned and a metal spray is applied to the surface porosity defects. The mask is removed and the restored surface porosity defects are hand finished to create an engine block having less than 0.05% surface porosity.

Abstract: Provided herein is a method for refining primary silicon present in a hypereutectic aluminum silicon alloy. The method contemplates the controlled application of pressure to refine the primary silicon during the casting of articles. The application of pressure decreases the primary silicon particle size to improve the machinability and wear resistance of the final cast articles.

Abstract: A method of cleaning and of heat treating lost foam castings utilizing a heated, fluidized sand bed is disclosed. The fluidized action of the sand, the movement of the casting through the sand and the heat of the bed, combine to remove residue coating resulting from the lost foam casting process from the casting.

Abstract: A hypoeutectic aluminum silicon casting alloy having a refined primary silicon particle size and a modified iron morphology. The alloy includes 10 to 11.5% by weight silicon, 0.10 to 0.70% by weight magnesium and also contains 0.05 to 0.07% by weight strontium. On cooling from the solution temperature, the strontium serves to modify the silicon eutectic structure as well as create an iron phase morphology change. Such changes facilitate feeding through the aluminum interdendritic matrix. This, in turn, creates a finished die cast product with extremely low levels of microporosity defects. The alloy may be used to cast engine blocks for marine outboard and stern drive motors. Furthermore, when the magnesium levels are adjusted to approximately 0.10 to 0.20% by weight magnesium, propellers having a highly advantageous ductility may be obtained.

Abstract: An apparatus and method to delay the application of pressure on a molten metal front to equalize a pressure gradient present at the molten metal front during pressurized lost foam casting processes, or other pressurized casting processes. A pressure equalization member is placed over a pouring cup to divert the direct application of pressure to molten metal present in the pouring cup. The pressure equalization member allows for increased pressurization rates in such processes, facilitating interdendritic feeding while reducing microporosity and metal penetration defects.

Abstract: A method for casting of metal articles using external pressure and having particular application to lost foam casting of metal articles. A polymeric foam pattern having a configuration corresponding to an article to be cast is placed in an outer flask and the pattern is connected through a polymeric foam gating system to a pouring cup located at the upper end of the flask. The pouring cup has a volume equal to 5% to 75% of the combined volume of the gating system and the pattern. A finely divided inert material, such as sand, is placed in the flask surrounding the pattern and fills the internal cavities within the pattern. The flask containing the pattern is then positioned in an outer pressure vessel having a removable lid and a molten metal is fed into the pouring cup.

Abstract: An investment cast stainless steel article, such as a marine propeller, is composed of a stainless steel alloy containing from 14.5 to 15.2% chromium, 5.35% to 6.05% nickel and 1.0% to 1.5% silicon.

Abstract: A method of casting hypereutectic aluminum-silicon alloys in an evaporable foam casting process with the application of pressure during the solidification of the alloy. A pattern is formed from a polymeric material having a configuration of an article to be cast. The pattern is supported in an outer mold and unbounded sand surrounds the pattern and fills the cavities within the pattern. The pattern is contacted with a molten hypereutectic aluminum-silicon alloy containing 16% to 30% silicon and having less than 0.8% copper. The molten alloy decomposes the foam pattern with the vapors of decomposition being entrapped within the interstices of the sand. While the alloy is in the molten state, gas pressure is applied to the alloy in the magnitude of 5 to 12 atmospheres to produce a cast alloy having less than 0.03% porosity and a high cycle fatigue strength greater than 13 KSI.

Abstract: An improved method of lost foam casting of aluminum silicon alloys utilizing a pattern formed of an expandable polymeric foam having a decomposition temperature less than 300.degree. C., and a heat of decomposition less than 600 Joules per gram. The foam pattern preferably has a heat of fusion less than 60 Joules per gram and a bulk density in the range of one to four pounds per cubic foot. The lost foam casting procedure has particular use when casting hypereutectic aluminum silicon alloys containing from 16 to 30% silicon, and eliminates the "liquid styrene" defect which occurs when casting such alloys in a lost foam process utilizing conventional polystyrene foam patterns. When casting hypoeutectic aluminum-silicon alloys containing from 5% to 8% silicon, the method eliminates the "fold" defect.

Abstract: A connecting rod for a two-cycle internal combustion engine that is composed of a hypereutectic aluminum-silicon alloy containing more than 12% silicon. The alloy contains precipitated particles of silicon having an average particle size less than 50 microns. In contrast to a hypoeutectic aluminum silicon alloy containing less than 12% silicon, the hypereutectic aluminum-silicon alloy has an endurance limit, so that at stresses below about 15,000 psi there will be no failure of the alloy at multiple cycles, making the alloy suitable for use as a connecting rod in a two-cycle engine, which is only subjected to compressive stress in service.

Abstract: A method of producing dimensionally predictable metal castings utilizing an expendable polymeric foam pattern along with unbonded sand having specific thermal properties. The pattern, formed of a material such as polystyrene, has a configuration corresponding to that of the article to be cast. The pattern is placed with an outer flask and unbonded sand surrounds the pattern as well as filling the cavities in the pattern. The sand has a linear expansion of less than 1% from 0.degree. C. to 1600.degree. C., a heat diffusivity greater than 1500 J/m.sup.2 /.degree.K/S1/2, an AFS grain fineness number of 25 to 33, and an AFS base permeability number of 450 to 500. A molten metal, such as an aluminum alloy or a ferrous alloy, is fed into the mold in contact with the pattern causing the pattern to vaporize with the vapor being entrapped within the interstices of the sand while the molten metal fills the space initially occupied by the foam pattern to produce a cast article.

Abstract: A method of producing a casting utilizing an expendable polymeric foam pattern along with unbonded sand having specific thermal properties. The pattern, formed of a material such as polystyrene, has a configuration corresponding to that of the article to be cast. The pattern is placed with an outer flask and unbonded sand surrounds the pattern as well as filling the cavities in the pattern. The sand has a heat diffusivity greater than 1500 J/m.sup.2 /.degree.K./s1/2. The molten hypereutectic aluminum silicon alloy is fed into the flask in contact with the pattern causing the pattern to vaporize with the vapor being entrapped within the interstices of the sand while the molten metal fills the space initially occupied by the foam pattern to produce a cast article. The thermal properties of the sand reduces the particle size of the precipitated primary silicon particles in the casting, thereby increasing the machinability of the casting.

Abstract: A hypereutectic aluminum-silicon alloy cylinder bore liner is produced by feeding the molten alloy into a metal mold having an inner shell sand cup, while rotating the mold at a speed in excess of 1,000 rpm, to cause the molten alloy to be thrown outwardly by centrifugal force to form a cylindrical liner. On solidification of the alloy, discrete silicon particles are precipitated and the use of the sand shell increases the fluid life of the alloy to enable the lighter weight silicon particles to migrate inwardly under the centrifugal force of rotation, to produce a solidified liner having a greater volume fraction of silicon particles in the inner portion of the liner where greater wear resistance is desired.

Abstract: A method of evaporable foam casting of metal articles, such as engine blocks for internal combustion engines. An evaporable foam pattern having a configuration proportionally identical to the article to be cast is positioned in a mold and a finely divided flowable material, such as sand, surrounds the pattern and fills the internal cavities of the pattern. A molten hypereutectic aluminum-silicon alloy containing 16% to 19.5% by weight of silicon and containing a magnesium content in excess of the magnesium solid solubility limit, is fed into the mold and into contact with the pattern. The heat of the molten metal vaporizes the pattern, with the vapor being trapped within the sand and the molten metal filling the void created by vaporization of the pattern to provide a cast article. The high magnesium content in the alloy produces in the solid state a Mg.sub.