The Bucket Foundry

[Gradella23]

Hello everyone,
I received a nice little gift from Voxeljet at the office today

[Brett S]

Nice, I'm pretty sure on facebook i saw Ian Harrison of Viper Racing use that technique of joining the water core to the rest of the printed cores as well.
Not sure if just for prototype cylinders or production.
Is there enough room to fit a cooling channel between the transfer and the bore?
How much did they cost if you don't mind me asking?

[Gradella23]

Nice, I'm pretty sure on facebook i saw Ian Harrison of Viper Racing use that technique of joining the water core to the rest of the printed cores as well.
Not sure if just for prototype cylinders or production.
Is there enough room to fit a cooling channel between the transfer and the bore?
How much did they cost if you don't mind me asking?

i paid 85€ excl. vat, but the same core would cost 19€+vat if i buy 10 of them and 25€ if i buy 5.
Obviusly the size plays a major role here, this part is 130x105x87mm.

the cooling channel on the inside of the transfer will be the next improvement for sure, i was only afraid about some cracking cause the biggest channel i can fit there is barely 5mm thick.
the next time i'll try that, i already have the updated model, and i'd also like to try a bridged exhaust.
but first of all i need to have the prototype casted.

[lodgernz]

Anyone know where I can buy some green casting sand in Wellington?

[Flettner]

Where is your nearest foundry? Fielding?

[lodgernz]

Where is your nearest foundry? Fielding?

Yes, Feilding or Palmy, but I was hoping to save a four hour trip. Must be someone in Welly?

[F5 Dave]

I can make some yellow sand. Might smell a bit when heated up.

I remember going to a foundry next to JJF when I was visiting them. Back in Seaview. Long gone by now. Erm, Neeles rings a vauge bell.

[ken seeber]

Here's a pretty cool process...with old mate "2 stroke Stuffing"

Looks like an ExOne sand printer is beyond the budget for a tinkerer. Neil, you could use one...

https://www.youtube.com/watch?v=CxiHRGwTKec

[Peter1962]

Not sure if these youtube video's concerning casting for Kreidler already passed here on the thread ?
https://www.youtube.com/watch?v=_zO27SWRMco

[husaberg]

Nearly all forged car or foul stroke motorbike pistons are either
High silicon is 4032
or
Low silicon is 2618.
The 2618 is stronger.

MTC use or at least used to use, a low silicon alloy that has incredibly small cold clearance I have no idea what it is.
Also interesting to see that the piston technology is heading back to ferrous metals.
You could say, they have turned full circle

The AC9C aluminium alloy is a specific grade of cast aluminium defined under the Japanese Industrial Standard (JIS H 5202). It is primarily an aluminium-silicon (Al-Si) based alloy with additions of copper (Cu) and magnesium (Mg), and is commonly used for general engineering and automotive applications due to its good balance of properties.
Composition and Properties
While the exact detailed composition was not immediately found in the snippets, AC9C is generally classified within the Al-Si-Cu-Mg family of casting alloys.
Key Properties:
Good castability: Suitable for complex shapes in sand and permanent mould casting processes.
Moderate strength: Offers adequate mechanical strength for a variety of general purpose applications.
Corrosion resistance: Like other aluminium alloys, it forms a protective oxide layer when exposed to air, enhancing its natural corrosion resistance.
Versatility: Considered a versatile alloy for general engineering parts.
Common Applications
AC9C is a general-purpose casting alloy, often utilized in applications where a balance of good mechanical properties and cost-effective casting is required.
Typical uses may include:
Automotive components like cylinder blocks and heads
General engineering parts
Pump and valve bodies

nternational EquivalentsAlloys with similar compositions and properties in other international standards might include:
USA (AA/UNS): A356 (A03560) is similar in some respects (Al-Si-Mg), though composition varies.
UK (BS): LM25 is a potential equivalent (Al-Si7Mg) for general-purpose use with good castability.
EU (ENAC): ENAC-AlSi7Mg is a comparable European grade

[Peter1962]

Jan Schaeffer and our favorite Norwegian made a very nice video on 3D printing sand casting cores for a two stroke cylinder. Impressive, to say the least.
https://www.youtube.com/watch?v=CxiHRGwTKec