Developments and Application of Expendable Salt Core Materials for High Pressure Die Casting to Apply Closed-Deck Type Cylinder Block

This paper describes a technique of manufacturing expendable salt cores developed to form undercut shaped aluminum closed deck cylinder block by high pressure die casting (HPDC) process. The salt cores are comprised of Potassium Chloride-Sodium Chloride-Sodium Carbonate-Potassium Carbonate system whose liquidus point is between 873 and 973K. The bending strength of the developed salt core was more than 30MPa. The manufacturing process of the salt cores was the HPDC similar to the process for metallic alloys. This process offered high dimensionality and productivity of the salt cores.