Custom Aluminum A356-T6 Engine Head Casting

Product Introduction

The custom engine head is made from gravity casting, also known as permanent mold casting, is critical to achieving the dimensional accuracy and structural integrity required for engine heads. Whether for racing engines, industrial power units, or automotive applications, our custom Aluminum A356-T6 engine head gravity casting delivers the precision, strength, and thermal performance needed to maximize engine efficiency and reliability.

Material and process

A356-T6 is the material of choice for high-performance engine heads, it is enable to withstand the cyclic mechanical stress of valve operations and combustion pressure after T6 heat treatment. And aluminum can dissipate heat from combustion chambers, reducing the risk of overheating and ensuring stable engine operation even under high loads.

Here are the engine head 3D drawings:

the engine head 3D drawings -1

the engine head 3D drawings -2

the engine head 3D drawings -3

Once the drawings are finalized, we focus on precision execution for this product,which weighs 2.4kg, with special expertise in addressing its core challenge: the small internal cavities as those pointed by the red arrows.

Just as its name implies, permanent mold casting needs a mold. So the mold is need to make first.

Molds are precision machined from high grade tool steel, designed to replicate intricate engine head features, including thin walled coolant jackets, tight tolerance valve guides, and flat sealing surfaces. 

Below are the molds of the engine head:

aluminum engine head mold-1

aluminum engine head mold-2

aluminum engine head mold-3

aluminum engine head mold-4

Then install the mold and test, the permanent mold is first cleaned and preheated to a controlled temperature. Preheating ensures proper metal flow, prevents cold shuts, and extends mold life. Release agents may also be applied to facilitate easy removal of the casting. 

The A356 aluminum material is melted in a furnace to a precise temperature. The molten metal is then poured manually or via automated ladles into a sprue. Gravity guides the metal through runners and gates into the mold's cavities, filling all details evenly.

Once filled, the mold and metal are allowed to cool. Cooling rates are controlled to avoid internal stresses or defects: thicker sections may cool more slowly, while thin walls solidify faster. After solidification, the mold is opened, and the casting is removed.Below is the rough casting engine head:

Post-casting steps include trimming excess material, heat treatment T6 aging for aluminum to enhance strength, and sandblasted.

Packing

Prior to packaging, we conduct thorough inspections covering critical aspects such as dimensional accuracy and surface quality to ensure every product meets our strict standards. For qualified products, we first wrap them tightly in bubble wrap to provide cushioning and protection against scratches or impacts during transit. These wrapped items are then carefully placed into sturdy cartons, the cartons are securely loaded onto pallets, where they are strapped down firmly to ensure stability during handling and transportation.