A company that produces internal combustion engines was in need to improve the productivity as well as to reduce the production cost for the manufacturing of sand cores for an aluminium cylinder head. To produce a cylinder head 2 different shapes of sand cores were necessary: Chain and Jacket.
The idea of combining the production of chains and jackets at the same time in one family mold seemed brilliant! It was a way to increase the productivity. However it turned out during the mass production that this option did not deliver a good result.
There were quality issue with both sand cores, the obvious reason was the significant different of the chain’s and jacket’s geometry. Both sand cores were produce using the same process parameter in the core shooting machine, which also contributed to the quality issue.
The jacket’s quality issues were unfilled areas as well as burnt surface. The chains had a significantly greater mass compare to the jackets suffered from uncured region which led to another problem during the handling and storage: the parts easily broke due to less mechanical properties. And also during the metal casting process: core gas problem in the aluminium part due to the high residue of the binder.