A Unique Cooling Approach Makes Aluminum Alloy Cylinder Heads Cost Effective

The objective of this paper is to introduce the design of a unique cooling approach for internal combustion engines which results in a major weight reduction with virtually no cost penalty.

This paper reveals details of a design that solves the problems of utilizing aluminum alloys instead of a cast iron alloys for internal combusion engine cylinder head material without incurring the large cost penalties currently associated with this procedure. This is accomplished by the invention of a unique cooling system that scientifically controls the operating temperature of all vital areas of the cylinder head without using a sand cored water jacket passage. Eliminating the sand water jacket core from the manufacturing process of making cylinder head castings also allows the sand exhaust port core to be eliminated. Elimination of these cores results in substantial cost savings over conventional cast aluminum alloy cylinder heads. Additional cost savings result from the simple push-in exhaust port liners that can be used with this concept plus the reduction of ten pounds of coolant in a 5 litre V-8 engine.

A complete analysis of the unique cooling system is presented. This analysis is backed up by experimental data on flow velocities, pressure drops in all coolant passages plus actual engine data which include a full temperature, heat balance, octane and durability comparison with cast-iron cylinder heads.