Contrary to popular belief, fusible-core tech-

Articles nology is as relevant to small runs as it is to

Fusible coring – volume production. Thanks to recent work,
the technology can be used to make anything
practical for forming down to a single component without neces-
one-off structures sarily incurring high costs in core casting,
injection moulding, or toolmaking. This
article reviews the state of the technology in
Glyn Morgan the light of developments aimed at enhancing
its economic appeal for modest production
needs.

The author
Glyn Morgan is with Mining and Chemical Products Ltd,
Whitchurch, UK.
Abstract
Reviews the state of fusible-core technology and describes
various techniques: core casting, overmoulding and melt-
out. Suggests that fusible coring for small runs can make a
product financially viable.
The technique
Fusible-core technology enables intricate
hollow parts to be moulded as unified compo-
nents in plastics, composites and rubbers. It
saves the cost and time of making the compo-
nent from a number of parts bonded together.
Additionally, fusible-cored components are
usually stronger than their multi-part equiva-
lents, possessing good structural integrity.
In the basic process a core of the compo-
nent interior is cast or made in a low-melting-
point alloy, which is overmoulded or overlaid
with the plastic or composite material. When
the overlay has cured, the core is melted out at
a temperature too low to damage the formed
component.

Aircraft Engineering and Aerospace Technology
Volume 69 · Number 2 · 1997 · pp. 145–146
MCB University Press · ISSN 0002-2667
145
Core casting
Alloys with melt temperatures from 47˚C to
300˚C are generally used for the cores. Non-
toxic formulations suitable for food-safe and
clean-air applications are also available.
In choosing an alloy, it is important to
reconcile its melting point with the tempera-
tures of overmoulding, curing and melt-out.
Mechanical properties should also be taken
into account (particularly for heavy cores and
those that must withstand injection-moulding
pressures). The ability of the alloy to repro-
duce the required finish on the interior sur-
face is also a consideration; so too are the
alloy’s effects on cycle times and energy con-
sumption.
The core can be made in a number of ways.
For high production volumes, the low pres-
sure core-casting machines employed by the
motor industry are probably best. However,
their expensive tooling and long setting-up
routines necessitate substantial runs for
© Glyn Morgan, 1997.
 Fusible coring – practical for forming one-off structures
Glyn Morgan
economic viability. Over the last two years,
studies have focused on ways of making cores
for runs that do not justify heavy investment.
One solution is to use a simple melting pot to
cast the cores by hand in moulds made in
sand, silicone rubber, high-temperature resin,
sprayed metal and glass-reinforced fibre.
Almost any size of core can be produced in
this way. One core from a grp mould weighed
64 kg.
This approach can result in appreciable
savings. In one case, the use of a grp mould
reduced tooling costs by 90 per cent and
toolmaking time by several days. The light-
ness of the mould also solved handling prob-
lems. Master patterns in cheap materials such
as wood, resin and plaster can be used for
making the moulds. Models produced by
rapid prototyping – stereolithography, fused
deposition or paper lamination – can also be
employed, although some surface preparation
may be necessary to improve the cored finish.
Overmoulding
The most widespread overmoulding practice
is to use a conventional injection-moulding
machine to inject a thermoplastic cyclically
into the mould containing the fusible core.
Here again, the approach is most cost-effec-
tive on substantial volumes. For much smaller
quantities, overmouldings can be wrapped
around or laid on the core by hand one at a
time. This is how aircraft ducting, control
cabinets and honeycomb structures are made
in composites.
This straightforward manual operation can
be extremely flexible. Designs can be modi-
fied after each shot, for example. Weak spots
shown up by the process can be rectified
during production, and inserts can be added
to the structure. Inconsistencies in the opera-
tion can be corrected by using a compression
or autoclaving curing mould. Even with this,
the technique’s costs are well below those for
fusible coring in volume.
Melt-out
Thermal conduction, induction heating, and
sometimes a combination of both are com-
monly used for melting cores out of the
formed components. The melt-out period
should be short enough to avoid exposing the
component to a temperature near its distor-
tion limit for any time. The method chosen
should also be sure to remove all traces of core
146
Aircraft Engineering and Aerospace Technology
Volume 69 · Number 2 · 1997 · 145–146
material, particularly in hygienic and food-
safe applications.
Some cores can be designed to help melt-
out. Hollow cores, for example, will reduce
melt-out times by allowing the thermal medi-
um to flow through the core centre. Much
lighter and easier to handle, they also reduce
distortion risks during moulding, and mini-
mize alloy usage. The melt-out tank provides
both heat source and a means of recycling
alloy for casting new cores. In low-volume
applications, one tank can serve as both dis-
pensing and melt-out facility. Alloy can be
recirculated continuously with little wastage,
allowing material costs to be amortized over
the total production.
Of the preferred heating methods, thermal
conduction permits metallic inserts to be
incorporated into the components. A pump
washing system can be added to ensure com-
plete removal of the core material. This circu-
lates the hot oil or glycol to counteract the
insulating effect of the plastic over-mould.
Most fusible alloys are good electrical
conductors and ideal subjects for magnetic
induction heating. This technique is not
suitable for components with metal parts,
which will heat up and separate from their
“beds”. The fixed orientation of the core to
the heating coil also inhibits complete removal
of the alloy. Where component design allows,
a combination of the two methods will proba-
bly be the most efficient melt-out procedure.
Hot-air chambers and ovens are generally
unsuitable. They are often inefficient to oper-
ate and expensive to run.
Benefits to small runs
Fusible coring can make a product financially
viable by eliminating costly operations in
producing a hollow component. Expenditure
can be further reduced by integrating plastic
and metal parts into the component at the
casting stage.
Recent work on core casting and over-
moulding has brought these benefits within
the reach of low-volume producers. The cost
of the technology can now be matched to the
quantities required, the existing plant, the raw
materials and the skills of the operators.
Details are available from Mining and
Chemical Products Ltd, The Mill House,
Laverstoke, Whitchurch, Hants RO27 7NS.
Tel: 01256 897200.