Casting a Racecar Cylinder Head - Complete Process 

Don't give up, go and get a job like that!😀

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Ok

Pp

3D printed most likely

3D printed

It was 3D printed, with a sandcore printer, I’m planning to make a video that cover’s this process.

@@longhorn261 Thank you for the sub. I'm working on several casting videos with 3D printed pattern, also investment casting, so stay tuned.

@@castingdesign1140 Come please my job survey mining nickel and gold..investasion come

Generally aluminium shrinks by 4% so when designing the patterns everything has to be 4% bigger in all directions. Then allow for machining, so faces that will be machined generally will have about 6mm added to them . Also it’s quite hard to centralise the casting when machining so on quite a long part like a cylinder head datum’s have to be checked. . What few people realise is that core plugs on bocks and cylinder heads are not there to stop the block cracking in a frost . They are there to support the cores ( cores for the cavities / water jackets ) . These can be clearly seen in the video. Quite hard to spot or understand if your not used to working in reverse/ negative. These are sand cast heads or old school ideal for small / medium batches . On some more modern engines they use pressure/ vacuum casting techniques usually injecting alloy from a large reservoir below and either forcing the material up and use a vacuum to get rid of the gasses . This improves quality and reduces chilling . Also on large batch production they will have a machine making the cores and a conveyor system to feed an automatic casting machine .

​@@newagetemplar6100 sir, where did you acquired that amazing knowledge?

@@chumbeque4561 hi , just through a lifetimes worth of engineering, I had a very good friend who had been a pattern maker all his life and used to go down at night to his workshop. All hand done using old school techniques , sand boxes , contraction rates / shrinkage etc etc . Then I had my own castings made for WRC alloy uprights and machined them myself. This also ran along side my fibreglassing skills that I had leaned previously. I am now building a BMW E36 GTR race car with all composite panels and alloy uprights . I’ve been very luck in that respect as YT wasn’t around in the early 90’s . Fortunately now there is a vast amount on YT for people not as fortunate as myself . Many thanks for your kind comment. 😇🇬🇧

@@newagetemplar6100 In the case of pressure/vacuum casting would the part still shrink ~4% or does it maintain the dimension after cooling? Similarly, would a tall sprue/feeder supply enough head pressure to decrease the shrinkage as it cools? also would pre-heating the sand mold have any affect on shrink rates if it is allowed to cool slower?

@@PhaseFabrication the shrink rate is a constant, thermal characteristic of the alloy. i have three rulers that are not allowed to be mixed up. brass, iron, aluminium. theyre precalibrated patternmakers rulers with the offset already applied. doesnt matter how its done, aluminium always shrinks a certain amount as it cools from a certain temperature.

Well, someone have to design and make the patterns so it can be filled correctly.

Hello, Yes they’re made with an ExOne printer.

@@castingdesign1140 excuse me ExOne printer How much does it cost? ... Thank you...

@@karnchan2589 we don’t own the printer we just ordered the prints but I believe it’s several hundreds of thousands of dollars

@@castingdesign1140 cool, i believe this uses resin bonded sand ? Do you sell core/molds made on order or you only offer casting process ? I would like to cast a head my self , this 3d print technology would save quite a hassle with draft requirments 😄😄

What's price for prints ?

We use NX for product abd tool design. Custmer's model was Creo

@@krisztianhernek685 thank you so much!

​@@krisztianhernek685, is this your factory?

We made cylinder heads similar to this for oldtimer motorbikes, I think it's possible but I need the design or a part that I can use to make the design.

@@castingdesign1140 Your work is awesome. Where do you do your work?

Way, way cheaper than machining billet.

@SomeTechGuy666 Maybe. Once a program is dialed in CNC is very efficient and fast. Once the chips are weighed and sold that is.

good way to recycle aluminum cans.

Don’t try this at home

It’s a special built Lada it will be a rally car.

Maybe the valve lift intentionally to be built higher than my grade

@Casting Design ohhhh. Sorry I'm use to drag racing stuff. We run big stuff

Hi. We are in Hungary. In Europe.

I appreciate your comment.

Magmasoft is a good casting sim software

You could be able cast from melted soda cans but that would be probably full with porosity. We use customer defined aluminium alloy.

Lol

Make them out of half-inch plate aluminum or steel

AlSi10Mg0,3

There is no 2nd part yet, it’s under production.

We didn't designed the part but I believe there is a good reason for why is it like this.

Hello

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