Low Melting Point Alloys and Applications

Make the impossible: multi cylinder inlet manifold ( Mercedes) in 35 % glass filled Nylon.
Photo shows from left to right: 1) the metal core in low melt alloy - 2) The metal core over moulded in plastic - 3 ) The finished component , internally undercut, impossible to produce with conventional tooling methods

MAKE THE IMPOSSIBLE - Fusible Core Technology with Scott AM Alloys

Fusible core technology is a modern and extremely effective process for realising internally undercut components in engineering plastics. The process requires two moulds. The first mould is used to cast the metal core in a low melt alloy.

The core is then placed in a regular injection mould and over moulded and later melted out in a high temperature fluid leaving behind a fully integral, internally undercut high strength plastic moulding. Some of the most popular applications for this process are impellers for water pumps, tennis racquets and automotive inlet manifolds where the extremely important internal surface geometry and finish can be dictated by the metal core. Extremely quick cycle times can be achieved as slow as 60 seconds per manifold which includes all operations of metal core casting over moulding and melt out.

Automotive Cylinder Head Water Jacket in Completely Transparent Plastic

Using the advantages of the Scott AM Vacuum Casting Process combined with one of Scott AM's low melt alloys is the perfect solution for producing the test bed prototypes for water flow testing. An alloy core is produced in silicone tooling with a melting temperature well under 100°C. A completely transparent, optically perfect vacuum casting resin is cast around the metal core using the vacuum casting process which offers completely void free castings and mouldings. The alloy core is then melted out in hot water leaving a hollow and internally undercut, one piece water jacket.

How the process works


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Legal notice: This video was found on YouTube, uploaded by Кирилл Казмирчук, May 13, 2015
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Text: Ron Simmonds / MCP-HEK

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