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In recent years, the automotive industry has been increasing the production of small, high-power gas engines as part of several strategies to achieve the new “Corporate Average Fuel Economy” (CAFE) standards. This trend requires an improvement in the thermal and mechanical fatigue durability of the aluminium alloys used in the production of the cylinder blocks in these engines. Conventionally, solid chills are employed in areas of these castings subject to high cyclic loading to enhance the mechanical performance of the cast material – i.e. in the main bearing bulkhead. A potential means of improving the efficacy of these chills is to incorporate water cooling. To assess the effectiveness of this method, a water-cooled chill was designed and installed in a bonded-sand engine block mould package (1/4 section). The moulds were instrumented with thermocouples, to measure the evolution of temperature at key locations in the casting, and “Linear Variable Displacement Transducers” (LVDTs), to measure the gap formation at the interface between the chill and the casting. This paper summarizes, at a high level, some of the findings of this work.

An investigation of the chill-casting interface dynamics in production of sand-cast A319 engine blocks