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[November 2001]
Morgan Advanced Ceramics Introduces Sacrificial Cores
Morgan Advanced Ceramics (MAC) has introduced a line of sacrificial cores. For use in industries such as automotive and aerospace, these cores are said to be the most cost effective way to cast complex cavities in components. As the compacted core is highly soluble, it can be flushed from the casting swiftly and completely with jets of high pressure warm water. The resulting solution is very dilute and can be treated by standard wastewater plant. The sacrificial cores give a surface finish better than 2 microns Ra (roughness average) to blind cavities within precision aluminium castings.
MAC's Engineering Manager Mat Cudd explained: "We have developed a dry compaction pressing technique that produces sacrificial cores of up to 150mm diameter by 50mm depth using a powder formula instead of a cast resin. It is a modification of a method we perfected some years ago for moulding complex ceramic components".
On medium volume batch production, this new process gives the cores a 2 micron Ra finish, which translates to an even finer surface inside the cast components. It is said to be ideal for casting galleries in aluminium pistons of diesel engines, where a fault-free surface is needed to eliminate stress raisers and a smooth precision shape is required for efficient oil flow.
"Our outstanding success with aluminium castings leads us to believe that the cores will also work effectively with other non-ferrous materials that have casting temperatures below about 800°C," adds Mat Cudd.
A special re-useable packing has also been developed to ensure that the cores are delivered to customers in pristine condition.
ENDS