Impact of Temperature of Cast Iron Chills on Tensile Properties in the Aluminum Precisions Sand Casting Process

The latest generation of high-performance cylinder blocks are produced with the Precision Sand Castings Process which sometimes uses a monolithic cast iron chill that promotes enhanced solidification conditions that improve both tensile and fatigue performance. However, monolithic chills tend to be re-used quite quickly and thus can be significantly above room temperature during the next subsequent casting. To deter the potential deleterious effects, this may cause most casting practitioners to enforce a strict room temperature condition of the chill prior to use. However, this may necessitate a higher number of chills in the system or the implementation of chill cooling stations, both of which involve higher capital investment. The authors will address the most optimal method to address thermal management of chills by documenting the mechanical and microstructural property impact and its compliance in the bulkhead (next to chill) and head bolt columns (60 mm away from the chill) to the chill temperature prior to casting. The Quality Index will reflect the chill temperature impacts based on the mechanical properties results for this manuscript.