Abstract: An internal combustion engine having an engine block containing a plurality of cylinder bores and a piston slidably mounted in each bore. The block is composed of a hypereutectic aluminum-silicon alloy containing from 16% to 30% silicon and having precipitated primary silicon crystals, while the piston is composed of an aluminum-copper alloy containing from 10% to 15% by weight of copper.

Abstract: A hypereutectic aluminum-silicon casting alloy having a refined primary silicon particle size and a modified silicon phase in the eutectic. The aluminum base alloy includes from 19% to 30% by weight of silicon and also contains 0.005% to 0.06% by weight of phosphorus, and 0.15% to 1.15% by weight of titanium. On cooling from solution temperature, the phosphorus serves as an active nucleant for the primary silicon phase, while at a lower temperature, a titanium-aluminum intermetallic compound is formed that is sheathed by the pseudoprimary .alpha.-aluminum and the sheathed particles act as a nucleant to modify the acicular silicon phase in the eutectic. The resulting alloy has primary silicon refinement coupled with eutectic silicon modification.

Abstract: A method of high pressure casting of hypereutectic aluminum-silicon alloys using a salt core to form wear resistant articles, such as engine blocks. To produce an engine block, one or more solid salt cores are positioned within a metal mold with the space between the cores and the mold defining a die cavity. A molten hypereutectic aluminum-silicon alloy containing more than 12% silicon is fed into the die cavity and on solidification of the molten alloy, precipitated silicon crystals are formed, which are distributed throughout the wall thickness of the cast part and also on the surface bordering the salt cores which constitute the cylinder bores in the cast block. The salt cores are subsequently removed from the cast block by contact with a solvent such as water.

Abstract: A two-cycle, water-cooled marine engine having an engine block composed of a hypereutectic aluminum-silicon alloy. The silicon is distributed as discrete particles throughout the block, including the area bordering the walls of the cylinder bores. An aluminum piston is mounted for movement within each cylinder bore and the outer peripheral surface of each piston is plated with iron. With the iron plated piston in combination with the aluminum silicon alloy engine block, the engine is capable of being restarted after the engine seizes due to overheating caused by a blockage of the water cooling system.

Abstract: A pattern for use in casting a rotatable shaft, such as a crankshaft for an internal combustion engine. The pattern includes an evaporable foam pattern section composed of a material such as polystyrene and having a configuration conforming to the crankshaft to be cast. The evaporable foam pattern section includes a plurality of cranks connected by bearing areas, and tubular metal inserts formed of bearing quality steel are disposed around each bearing area and around the pin areas of the cranks. In the casting process, the pattern is placed in a mold and surrounded with a finely divided material such as sand. When molten ferrous metal is fed into contact with the pattern, the pattern will vaporize with the vapor passing into the interstices of the sand while the molten ferrous metal will occupy the void created by the vaporized foam to produce a cast crankshaft having bearing quality steel inserts at the bearing and pin areas.

Abstract: A lost foam casting system (2) is provided with vacuum lift of molten metal (16) to an evaporative foam pattern assembly (8) surrounded by unbonded particulate media such as sand (6) in a flask (4). A gas permeable member (34, 70) formed of randomly oriented ceramic fibers is provided between the sand and a vertical fill passage (20) to apply vacuum from the sand to the fill passage such that molten metal is vacuum lifted through the fill passage to the foam pattern assembly. The foam material is vaporized by the heat of the molten metal as the metal advances upward and is replaced by the metal in the shape of the pattern assembly.

Abstract: A hypereutectic aluminum silicon alloy having an improved distribution of primary silicon in the microstructure. The alloy is composed by weight of 20% to 30% silicon, 0.4% to 1.6% magnesium, up to 1.4% iron, up to 0.3% manganese, 0.25% copper maximum and the balance aluminum. With this composition the aluminum silicon alloy system exhibits near zero shrinkage on solidification, a similarity of the liquid aluminum-silicon alloy and the primary silicon during the early stages of primary silicon precipitation, and thereby minimizes floatation of the precipitated primary silicon and to provide a more uniform distribution of the primary silicon in the microstructure and increase the wear resistant characteristics of the alloy.

Abstract: A method of casting utilizing an evaporable foam system with a hypereutectic aluminum silicon alloy. The molten alloy is introduced into a mold in contact with an evaporable foam pattern formed of polystyrene, or the like. The heat of the molten alloy will decompose and vaporize the pattern and the vapor will enter the interstices of the surrounding sand, while the molten alloy will fill the void caused by the vaporization of the pattern. By casting the molten alloy into contact with the evaporable foam material, a more uniform distribution of primary silicon is obtained in the cast alloy and the heat of crystallization caused by precipitation of silicon crystals on solidification of the alloy will temporarily slow the solidification rate of the alloy, thus increasing the time for elimination of pattern residue vapors from the molten alloy.

Abstract: A method of producing titanium. A quantity of titianium is heated in a crucible to provide a melt, and a layer of slag, containing an ionizable titanium compound, such as titanium dioxide, along with ionizable slag constituents, is disposed on the top of the melt. The slag is then heated to a molten state by direct current plasma arc heating with the melt being anodic. After the slag is molten, the polarity of the plasma arc heating is reversed so that the melt is cathodic, causing the slag to act as an electron transfer layer so that the titanium dioxide of the slag is reduced to titanium and any dissolved oxygen in the melt is converted to an ionic species of oxygen at the interface between the slag and the melt. The resulting liquid titanium is combined with the melt, while the ionic species of oxygen is carried upwardly through the slag and released from the slag layer by an oxidation process.

Abstract: A pattern, identically proportional in configuration to the salt core to be produced, is initially formed from an evaporable foam material. The evaporable foam pattern is positioned in a mold and surrounded with an unbonded flowable material, such as sand. The pattern is contacted with a molten salt and the high temperature of the salt will vaporize the pattern, with the vapor being captured within the interstices of the sand while the molten salt will fill the void created by vaporization of the foam to provide a salt core identical in configuration to the pattern. The salt core is subsequently used in a high pressure die casting operation to cast a metal part.

Abstract: A method of producing titanium. A quantity of titanium is heated in a crucible to provide a melt, and a layer of slag, containing an ionizable titanium compound, such as titanium dioxide, along with ionizable slag constituents, is disposed on the top of the melt. The slag is then heated to a molten state by direct current plasma arc heating with the melt being anodic. After the slag is molten, the polarity of the plasma arc heating is reversed so that the melt is cathodic, causing the slag to act as an electron transfer layer so that the titanium dioxide of the slag is reduced to titanium and any dissolved oxygen in the melt is converted to an ionic species of oxygen at the interface between the slag and the melt. The resulting liquid titanium is combined with the melt, while the ionic species of oxygen is carried upwardly through the slag and released from the slag layer by an oxidation process.

Abstract: A lost foam casting system (2) is provided with vacuum lift of molten metal (16) to an evaporative foam pattern assembly (8) surrounded by unbonded particulate media such as sand (6) in a flask (4). A gas permeable member (34, 70) or passage (72, 74) is provided between the sand and a vertical fill passage (20) to apply vacuum from the sand to the fill passage such that molten metal is vacuum lifted through the fill passage to the foam pattern assembly, such that the foam material vaporizes as the molten metal advances upward and is replaced by the metal in the shape of the pattern assembly.

Abstract: A hypereutectic aluminum-silicon casting alloy having particular use in casting cylinder blocks for marine engines. The alloy is composed by weight of 16% to 19% of silicon, 0.4 to 0.7% magnesium, up to 0.37% copper and the balance aluminum. With the stated silicon content the alloy has good fluidity and the precipitated silicon crystals provide excellent wear resistance. In addition, the alloy has a narrow solidification range of less than 150.degree. F., thereby providing the alloy with excellent castability. The copper content is maintained at a minimum so that the alloy has improved resistance to salt water corrosion.

Abstract: A lost foam casting system (2) is provided with vacuum lift of molten metal (16) to an evaporative foam pattern assembly (8) surrounded by unbonded particulate media such as sand (6) in a flask (4). A gas permeable member (34, 70) or passage (72, 74) is provided between the sand and a vertical fill passage (20) to apply vacuum from the sand to the fill passage such that molten metal is vacuum lifted through the fill passage to the foam pattern assembly, such that the foam material vaporizes as the molten metal advances upward and is replaced by the metal in the shape of the pattern assembly.

Abstract: A hypereutectic aluminum-silicon casting alloy having particular use in casting cylinder blocks for marine engines. The alloy is composed by weight of 16% to 19% of silicon, 0.4 to 0.7% magnesium, up to 0.37% copper and the balance aluminum. With the stated silicon content the alloy has good fluidity and the precipitated silicon crystals provide excellent wear resistance. In addition, the alloy has a narrow solidification range of less than 150.degree. F., thereby providing the alloy with excellent castability. The copper content is maintained at a minimum so that the alloy has improved resistance to salt water corrosion.