Production of GG25 based cast iron engine blocks and investigation of the properties

The engine block is the main structure of the internal combustion engine systems. Crank and camshafts, pistons, valve tappets, etc. many engine parts work in this block. It's the largest part of the engine system and generates for 20-25% of the total weight. The selection of material is required to meet the high strength requirement with low weight, which is important for the power of the engine. Also; Wear resistance, long service life, resistance to pressure cycles when combustion and explosion occur, and resistance to high temperature and vibration in working conditions are the main requirements. Compared to gasoline engines due to its high strength, the material is more critical for diesel engines with high compression ratios. In diesel-fueled engines that work with 20:1, not 10:1 like gasoline engines, attention is paid to the high strength of the material, not its low weight. In addition, at high operating temperatures to give off heat quickly; It should have high thermal conductivity and low thermal expansion properties. It should have good machinability in order to keep the time and cost at the optimum level in the machining process that continues after casting. Internally rotating components such as the crankshaft and piston are a high source of vibration, so the vibration damping ability of the material is also a critical material selection parameter. In this study, GG25 gray cast iron material working with diesel fuel; the production processes of a 3-cylinder Engine Block used in the agricultural machinery, generators, maritime and construction machinery sectors have been scrutinized. The use of solid modeling software in the design phase, engineering calculations related to casting and computer aided simulation applications are discussed. Core production processes with automatic core production machines, molding, core placement, casting and mold breaking processes in a casting production line producing with the fully automatic green sand molding method were examined, dimensional and material controls of the product according to customer specifications were examined specifically for the motor block part. Keywords; Diesel fuel, engine block, casting, gray cast iron