A first die segment for forming an internal combustion engine block has cylindrical projections, and die core pieces disposed about the cylindrical projections. A second die segment has die core stubs positioned so as to extend between adjacent die core pieces when the segments are brought together. An engine block formed by the die segments has cylindrical bores formed by the cylindrical projections extending from the deck of the block and voids formed by the die core pieces also extending from the deck and disposed about the cylindrical bores. Pockets formed by the die core stubs extend into sides of the engine block between adjacent voids. The engine block is worked below the level of the deck to undercut each of the pockets, removing material between them and the voids to result in an interconnected water jacket extending about the cylindrical bores, while leaving the deck closed.

A first die segment for forming an internal combustion engine block has cylindrical projections, and die core pieces disposed about the cylindrical projections. A second die segment has die core stubs positioned so as to extend between adjacent die core pieces when the segments are brought together. An engine block formed by the die segments has cylindrical bores formed by the cylindrical projections extending from the deck of the block and voids formed by the die core pieces also extending from the deck and disposed about the cylindrical bores. Pockets formed by the die core stubs extend into sides of the engine block between adjacent voids. The engine block is worked below the level of the deck to undercut each of the pockets, removing material between them and the voids to result in an interconnected water jacket extending about the cylindrical bores, while leaving the deck closed.

A method of casting an assembly is provided that includes forming a structural insert, over-molding the structural insert with a temporary core, and positioning the over-molded structural insert within a cavity of a casting die. The over-molded structural insert is cast within a part, to form the assembly, and the temporary core is removed. The method may also include a temporary core configured to define an alloy flash trim location or locating features to position the structural insert within the cavity of the casting die. Further, the temporary core may define shared features with the structural insert. The part and structural insert may be dissimilar materials such as a part of an aluminum alloy material and a structural insert of a steel alloy material.

A method of casting an assembly is provided that includes forming a structural insert, over-molding the structural insert with a temporary core, and positioning the over-molded structural insert within a cavity of a casting die. The over-molded structural insert is cast within a part, to form the assembly, and the temporary core is removed. The method may also include a temporary core configured to define an alloy flash trim location or locating features to position the structural insert within the cavity of the casting die. Further, the temporary core may define shared features with the structural insert. The part and structural insert may be dissimilar materials such as a part of an aluminum alloy material and a structural insert of a steel alloy material.

Embodiments of the present technology include molding processes for metallic foams, apparatuses, and products. An example method includes placing an uncompressed charge of conductive metal foam into a cavity disposed on a first tool, wherein the first tool is located on a first portion of a compression mold apparatus, translating the first portion of the compression mold apparatus towards a second portion of the compression mold apparatus so as to compress the uncompressed charge of conductive metal foam, creating a compressed charge of conductive metal foam, and overmolding around and through the compressed charge of conductive metal foam with an overmolding material.

A three-plate pressure die casting mold for producing at least one metallic die casting part by die casting a metal melt, includes first, second and third mold parts and at least one mold cavity as well as a sprue system. A relatively movable pressure plate is arranged in the third mold part, which, when opening the die casting mold, presses the sprue produced in the sprue system against the first mold part, whereby the sprue is retained and tears off from the die casting part in a defined manner. A method for pressure die casting using the three-plate pressure die casting mold is disclosed.

A three-plate pressure die casting mold for producing at least one metallic die casting part by die casting a metal melt, includes first, second and third mold parts and at least one mold cavity as well as a sprue system. A relatively movable pressure plate is arranged in the third mold part, which, when opening the die casting mold, presses the sprue produced in the sprue system against the first mold part, whereby the sprue is retained and tears off from the die casting part in a defined manner. A method for pressure die casting using the three-plate pressure die casting mold is disclosed.

Provided is a casting mold with which it is possible to apply air-blow to a bottom part of a groove in a core without moving forward/backward the core relative to the mold body. This casting mold is provided with a first mold and a second mold for forming, between the first mold and the second mold, a cavity used to produce a cast article, wherein the second mold has a second mold body and a core, which protrudes from the second mold body in a first direction toward the first mold and is used to forms a hollow part in the cast article, the core is provided with a groove part that opens in the first direction and is recessed in a second direction opposite from the first direction, and the second mold is provided with an air supply flow passage for supplying air for blowing toward a bottom part of the groove part.

Provided is a casting mold with which it is possible to apply air-blow to a bottom part of a groove in a core without moving forward/backward the core relative to the mold body. This casting mold is provided with a first mold and a second mold for forming, between the first mold and the second mold, a cavity used to produce a cast article, wherein the second mold has a second mold body and a core, which protrudes from the second mold body in a first direction toward the first mold and is used to forms a hollow part in the cast article, the core is provided with a groove part that opens in the first direction and is recessed in a second direction opposite from the first direction, and the second mold is provided with an air supply flow passage for supplying air for blowing toward a bottom part of the groove part.

A system and method of using a smart insert pin for making a casting for a vehicle, in which the casting includes a boss having internal threads. The system includes a mold and an insert pin insertable into the mold. The mold includes a portion of a mold cavity defining a boss shaped cavity and a bore in communication with the boss shaped cavity. The insert pin includes a first portion having external threads and a second portion extending from the first portion. The second portion of the insert pin is insertable into the bore with the first portion extending into the portion of the mold cavity defining the boss shaped cavity. The mold cavity is fill with a molten metal. The molten metal is cooled into a solidified casting. The insert pin is unfastened from the casting leaving a cast boss with an internal threaded bore.