Abstract: A casting chamber configured to form a casting from molten material includes an outer mold, a plurality of inner core elements, and a surface portion of a thermal chill device. The thermal chill device includes first and second interchangeable elements with the surface portion of the thermal chill device including one of a first surface portion of the first interchangeable element and a second surface portion of the second interchangeable element. The first surface portion of the first interchangeable element includes an insulating material and the second surface portion of the second interchangeable element comprising a metallic material.

Abstract: A method of casting an engine block of aluminum whose working surfaces, after milling the interiors of the cylinders, are coated with a harder metal, particularly nickel, includes inserting permanent molds in the sand mold and manufacturing the cylinder interiors of a metal which has a thermal expansion coefficient of greater than 18.times.10.sup.-6 K.sup.-1.

Abstract: A chill device for combination with a vaporizable pattern for casting metal by a lost foam process comprises a chill body receivable within a bore of the pattern and including a plurality of outwardly extending fins. The fins define channels therebetween for packing with mold sand to shape the cast metal and for venting pattern decomposition vapors during casting to avoid pore-forming entrapment in the cast metal. Also, the fins contact the bore surface to conduct heat into the chill body from the cast metal about the bore to accelerate solidification and thereby reduce shrink porosity. Thus, the chill device of this invention produces pore-free metal in the casting region immediately about the bore.