Thin-Wall Steel Casting Process for Exhaust Components

This paper describes a newly developed high production, commercial, and economical metal casting process for steel and alloyed steel, capable of producing thin wall casting section sizes of 2-3mm.

The Convert Mold Process was developed to meet the needs of automotive engineers and designers assigned the responsibility of reducing weight and using alternative materials that can withstand higher exhaust operating temperatures for the internal combustion engine. The process provides an opportunity to combine engine components through the utilization of a flexible casting process for steel and it's alloys.

Typical applications of these thin wall, steel and alloyed steel components include: exhaust manifolds, catalytic converter canisters, manifold/converter combinations and manifold/turbo combinations.