engine head construction 1

[gcomyn]

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?

 

[MikeHalloran]

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

 

[gcomyn]

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