Automotive Prototype Foundry Starting with CGI

An aftermarket auto parts venture is adopting SinterCast process control technology for compacted graphite iron (CGI) production. ACE MFG LLC is an offshoot of ACE Inc., a performance engineering and automotive parts business that is starting the foundry operation in Wixom, MI, to cast prototypes. Casting CGI cylinder blocks is the new foundry’s first objective.

“ACE manufacturing was started to bring to market some high-performance engine blocks and cylinder heads for the Gen III Hemi market. That was really our first target,” according to ACE Inc. president Eric Cunningham.

The Gen III Hemi engine is an engine developed by Chrysler that offers V8 power with more modern functions like fuel injection and electronic engine management – and it’s a popular aftermarket choice for individuals seeking to gain greater engine power for their vehicles.

“Casting components made with CGI provides at least 75% higher tensile strength and twice the fatigue life of gray iron, resulting in a lighter package built to handle the cylinder pressures that modern high-output engines are generating,” Cunningham said.

CGI is a lightweight cast iron that offers greater tensile strength, stiffness, and fatigue strength than gray iron or aluminum. Stockholm-based SinterCast developed and licenses the most widely adopted process technology for melting CGI.

But sourcing CGI for its automotive castings in the U.S. proved rather difficult, Cunningham explained, which led to the plan to set up a low-volume metalcasting operation.

“That's the plan we're on now,” he continued, “… with SinterCast in the mix for CGI, and we're looking at doing really anything below probably 1,000 units a year on engine block and their heads, (plus) military applications, really whatever comes through the door.”

ACE MFG LLC aims to melt and cast aluminum A356 and A357 alloys too, in the future.

The rest of the new foundry includes a 500-kg induction furnace and 500-kg treatment ladle. Sand patterns will be 3D printed under contract with various providers. Cunningham noted that some plans are in discussion for a cold-box and resin-set coremaking system, and a four-axis horizontal CNC machine will handle engine machining. Local shops will be enlisted for additional machining requirements.  

Later this month SinterCast will be delivering its Mini-System is a thermal analysis unit, a version of the SinterCast process developed specifically to support product development, prototyping, and niche volume production of CGI. Commissioning of the Mini-System will take place during Q3, and SinterCast will provide training and technical support as ACE establishes its prototyping process.

“The ACE MFG order is an excellent addition to the SinterCast customer family. We routinely field requests for options for CGI casting prototypes and niche volume production in the U.S. from OEMs and aftermarket companies,” commented Dr Vítor Anjos, president and CEO of SinterCast. “We share Eric’s passion for high-performance engines, and we know that CGI is a key material for unlocking higher levels of performance and efficiency.”