Metallurgical Aspects of Aluminum Lost Foam Automotive Castings

Metallurgical aspects of the lost foam aluminum casting process used for production of 4-cylinder engine blocks and cylinder heads are presented. Results represent a high-volume lost foam foundry producing a common alloy, AA 319.0-T5, for all components. The influence of proper chemistry selection, degassing of liquid aluminum and heat treatment on casting microstructure and material properties are reviewed. The material properties include hardness, tensile strength, elongation, low and high cycle fatigue strength.