Since this is a development project, Lodi Iron Works and I have an agreement that production comes first (Production pays the bills), and this project is a fill in job. When the ball is in my court to make a change, I do my best to make pattern and core box changes in a timely manner in order to pass the ball back to Lodi Iron Works.
Lodi Iron Works has been very busy with production this summer, and just this last week was able to resume work on this project.
On Nov. 19, members of FAST are planning a visit to my facility to view castings and tooling, and discuss and ask questions regarding the new Model A engine project. If you would like to join us, please reply by Email.
October 2011
Cylinder Block
8 Castings have been poured to date.
The first casting filled through the parting line at a very slow rate and had no porosity. The casting had other major problems like broken cores and core shift, so porosity was not an issue. Lodi Iron Works reworked the gating scheme in preparation for casting 2.
During the second through forth castings, all efforts were directed towards solving the broken cores and core shift problems, and porosity was not a big concern. Several core box changes were made during this period to optimize core print fit and insure adequate casting wall thickness.
The first time porosity was addressed was at the technical meeting following casting 4.
Various schemes for venting entrapped air were tried on castings 5 through 7, and none of them worked. The core boxes were further refined during this period to make it easier to remove the cores, and reinforcements were added to the core prints to make them stronger. Also, during this period, a procedure for core assembly was implemented, special tools were made to verify core position during assembly, and other aids to obtain consistent castings while reducing labor were implemented.
Casting 8 was poured last week. Several changes were made from casting 7 in an attempt to solve the porosity problem. Gating was cut by hand to introduce hot iron into the lowest part of the casting. Risers were added to the surface of the casting that had the porosity. Chaplets were added to insure position the valve chamber cavity core, and there were no vents.
Casting 8 had porosity in the same place. For those familiar with foundry terminology, I need to say that porosity means the same thing as “broken”. There are many different causes of porosity just like there are many different causes of broken. The porosity that is the problem comes from the hot iron vaporizing the core binders and the glue used to hold the cores together.
A technical meeting was held at Lodi Iron Works on Oct 24 to analyze casting 8, discuss the porosity problem, and brain-storm ideas for casting 9. The plan for casting 9 is not finalized, but changes will be made to slow the pouring rate (to a speed like casting 1) and possibly change the gating design to use horn gates. During these technical meetings, everything is discussed in an effort to make a better casting at a lower cost.
I have an unanswered Email sent to Lodi Iron Works asking for their plan for casting 9 along with a schedule guess.
Connecting Rod, Main Caps, and Crankshaft
The material used to cast these parts was Meehanite SP80 (80-55-06). This material is close to the material used for these parts in modern engines. This material is also used for suspension parts in new cars.
Good castings of these parts for the new Model A engine have been made and are awaiting a good cylinder block casting so all can go together to machine shops for bids on machining.
Next Update
The next update will be in about 2 months or sooner if casting 9 is good.
Terry Burtz, Campbell, Calif.
Lodi Iron Works has been very busy with production this summer, and just this last week was able to resume work on this project.
On Nov. 19, members of FAST are planning a visit to my facility to view castings and tooling, and discuss and ask questions regarding the new Model A engine project. If you would like to join us, please reply by Email.
October 2011
Cylinder Block
8 Castings have been poured to date.
The first casting filled through the parting line at a very slow rate and had no porosity. The casting had other major problems like broken cores and core shift, so porosity was not an issue. Lodi Iron Works reworked the gating scheme in preparation for casting 2.
During the second through forth castings, all efforts were directed towards solving the broken cores and core shift problems, and porosity was not a big concern. Several core box changes were made during this period to optimize core print fit and insure adequate casting wall thickness.
The first time porosity was addressed was at the technical meeting following casting 4.
Various schemes for venting entrapped air were tried on castings 5 through 7, and none of them worked. The core boxes were further refined during this period to make it easier to remove the cores, and reinforcements were added to the core prints to make them stronger. Also, during this period, a procedure for core assembly was implemented, special tools were made to verify core position during assembly, and other aids to obtain consistent castings while reducing labor were implemented.
Casting 8 was poured last week. Several changes were made from casting 7 in an attempt to solve the porosity problem. Gating was cut by hand to introduce hot iron into the lowest part of the casting. Risers were added to the surface of the casting that had the porosity. Chaplets were added to insure position the valve chamber cavity core, and there were no vents.
Casting 8 had porosity in the same place. For those familiar with foundry terminology, I need to say that porosity means the same thing as “broken”. There are many different causes of porosity just like there are many different causes of broken. The porosity that is the problem comes from the hot iron vaporizing the core binders and the glue used to hold the cores together.
A technical meeting was held at Lodi Iron Works on Oct 24 to analyze casting 8, discuss the porosity problem, and brain-storm ideas for casting 9. The plan for casting 9 is not finalized, but changes will be made to slow the pouring rate (to a speed like casting 1) and possibly change the gating design to use horn gates. During these technical meetings, everything is discussed in an effort to make a better casting at a lower cost.
I have an unanswered Email sent to Lodi Iron Works asking for their plan for casting 9 along with a schedule guess.
Connecting Rod, Main Caps, and Crankshaft
The material used to cast these parts was Meehanite SP80 (80-55-06). This material is close to the material used for these parts in modern engines. This material is also used for suspension parts in new cars.
Good castings of these parts for the new Model A engine have been made and are awaiting a good cylinder block casting so all can go together to machine shops for bids on machining.
Next Update
The next update will be in about 2 months or sooner if casting 9 is good.
Terry Burtz, Campbell, Calif.
