Custom Aluminum Sand Casting Intake Manifold Phenum

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Custom Aluminum Sand Casting Intake Manifold Phenum

Custom aluminum sand casting intake manifold plenum is a precision-engineered component designed to optimize airflow into an engine's combustion chamber, crafted specifically using sand casting techniques for aluminum alloys. Tailored to unique engine specifications, this plenum serves as a critical part of the intake system, distributing air evenly to each cylinder to enhance performance, efficiency, and power output.


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Product Description

Product Introduction

This is a intake manifold plenum used in the automotive industry. By leveraging the flexibility of aluminum sand casting, custom intake manifold plenums deliver tailored performance, durability, and fit, making them a cornerstone of high-performance engine design.

intake manifold plenum rough castings after deburrs-1

Material and process

The plenum is made from aluminum material.High-grade aluminum alloys are chosen for their lightweight properties, excellent thermal conductivity and corrosion resistance. Aluminum's machinability allows for post-casting refinements, ensuring tight tolerances for seamless integration with other intake components.

Sand Casting is a long history and widely used casting process. It forms a cavity through a sand mold and pours molten metal into it to cool and solidify. It is suitable for the production of various metal materials, such as cast iron, cast steel, aluminum alloy, copper alloy, and complex-shaped parts.

The process begin with making the outer mold, the outer mold is made from steel material.

intake manifold phenum outer mold-1

intake manifold phenum outer mold-2

intake manifold phenum outer mold-3

Next we move up to make the sand core mold. According to the shape and size of the casting, a model consistent with the shape of the casting is made to form the cavity of the sand mold. If there are holes or complex cavities inside the casting, a core box needs to be made, and the sand core will be placed in the sand mold to form the inner cavity of the casting. The pattern and core mold need to take into account the shrinkage rate of the molten metal, and their dimensions should be slightly larger than those of the casting. The surface needs to be smooth to ensure the accuracy of the sand mold cavity.

Here are the pictures of the sand core mold:

intake manifold phenum sand core mold-5

The mixture used for making sand molds mainly consists of quartz sand, binders, such as clay, resin, water glass, etc., and additives. The mixture used for manufacturing sand cores, which requires higher strength, air permeability and collapsibility, and usually has a higher proportion of binder. Mix sand, binder and additives in proportion, and stir evenly through a sand mixer. Control the moisture content and compaction to meet the molding requirements.

Fill the core sand into the core mold and compact it by means of core shooting. If binders such as resin or water glass are used, the sand core needs to be hardened by heating or blowing air to enhance its strength. After removing the sand core, trim the burrs. Some sand cores need to be dried to remove moisture and prevent the formation of pores during pouring.

intake manifold plenum sand core

Place the sand core into the cavity of the sand core mold, ensuring its accurate position, to form the inner cavity or complex structure of the casting. Close the upper and lower sand boxes to combine the cavity and core of the sand mold into a complete casting mold. Fix the sand core mold with clamps or bolts to prevent the wrong boxes or fire leakage during pouring.

The aluminum raw materials are heated to a liquid state in a furnace, impurities are removed, and the composition and temperature are adjusted. Pour qualified molten aluminum smoothly into the cavity of the mold along the runner to ensure that the cavity is fully filled with molten metal and avoid defects such as underfilling and cold shuts.

After the casting cools to a certain temperature, break the sand mold and remove the casting.

Below is the picture of rough castings:

intake manifold plenum rough castings

Remove the residual molding sand and sand core on the surface of the casting. Remove the gate and riser, grind burrs and flash to make the surface of the casting smooth.

intake manifold plenum rough castings after deburrs-1

The plenums after shot blasted, there are not uniform surface and the customer has high requirement of surface:

the plenum before polishing the plenum before polishing 1

Finally these intake manifold plenum are sent for polishing treatment, check from below pictures:

intake manifold plenum polishing surface

Packing

Each item is packed individually in a bubble bag and place them into wooden cases. The wooden cases are made of composite boards and are exempt from fumigation. This packaging method ensures that each product is well-protected against impacts and vibrations during transportation.

packed in wooden case