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engine head construction

engine head construction

engine head construction

(OP)
I recently replaced the cracked head of my Saturn.  I had not taken a good look at it before.  It looks like it is made of aluminum styrofoam - lots of little beads all brazed together.

Does anyone know what manufacturing process this is and how do they make it?

RE: engine head construction

It's called a 'lost foam' casting.  

The 'beads' you see are replicas of the plastic beads in the original foam.  The metal underneath them is quite solid.

http://en.wikipedia.org/wiki/Lost-foam_casting

Mike Halloran
Pembroke Pines, FL, USA

RE: engine head construction

(OP)
Oh, I don't doubt that it is solid.  Thanks for the answer!  Now I know why it looks like styrofoam.

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