Manufacture of Composite On-Engine Parts by the Meltable Metal Core Process

The meltable metal core process is examined as a means of producing cost-effective, composite on-engine components. Each step of the process is studied using water pump housings molded from Rogers' Moldable Phenolic Composites (MPC™) with Sn/Pb/Sb alloy cores. With proper control of core surface, core temperature and mold temperature, excellent moldings can be produced at tight tolerances. Process data and control techniques are presented.