JP2003191048A - Sand core for casting and its manufacturing method - Google Patents

Sand core for casting and its manufacturing method

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Publication number
JP2003191048A
JP2003191048A JP2001393901A JP2001393901A JP2003191048A JP 2003191048 A JP2003191048 A JP 2003191048A JP 2001393901 A JP2001393901 A JP 2001393901A JP 2001393901 A JP2001393901 A JP 2001393901A JP 2003191048 A JP2003191048 A JP 2003191048A
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JP
Japan
Prior art keywords
core
coating layer
casting
slurry
sand core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP2001393901A
Other languages
Japanese (ja)
Other versions
JP3581687B2 (en
Inventor
Shigemitsu Nakabayashi
Atsushi Suzuki
Mitsuaki Ueno
Tetsuji Umemoto
光明 上野
繁光 中林
哲司 梅本
篤 鈴木
Original Assignee
Honda Motor Co Ltd
本田技研工業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Honda Motor Co Ltd, 本田技研工業株式会社 filed Critical Honda Motor Co Ltd
Priority to JP2001393901A priority Critical patent/JP3581687B2/en
Publication of JP2003191048A publication Critical patent/JP2003191048A/en
Application granted granted Critical
Publication of JP3581687B2 publication Critical patent/JP3581687B2/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sand core for casting which can obtain a cast product excellent in a dimensional precision and also, easily separates from the cast product and easily collapses, and its manufacturing method. <P>SOLUTION: This sand core 10 has three-layer structures laminated with a first coating layer 14 on the surface of a core body 12 and a second coating layer 16 in this order. In these layers, a part in the first coating layer 14 containing large grain diameter zircon flower, small grain diameter zircon flower and phenolic resin is embedded into the core body 12. Further, in the second coating layer 16 coating this first coating layer 14, mica is contained as a lubrication-giving agent. Then, the core body 12 is constituted by combining 'Thera Beads' (an artificial sand) grain with the phenolic resin. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sand core for casting and a method for producing the same, and more specifically, it is possible to obtain a cast product having excellent dimensional accuracy and to easily separate the cast product from the cast product. Moreover, the present invention relates to a sand core for casting which is easily disintegrated and a method for producing the same.

[0002]

2. Description of the Related Art The production of aluminum castings by the die casting method involves placing a sand core in the cavity and closing the mold.
Then, the molten aluminum is introduced into the cavity at high pressure and high speed, and then the molten metal is cooled and solidified. At this time, a hollow portion having a shape corresponding to the shape of the sand core is formed in the cast product.

The sand core is generally manufactured as follows. That is, first, silica sand (SiO 2 is the main component), zircon sand (silicon and zirconium composite oxide), chromite sand (iron and chromium composite oxide is the main component), and high alumina sand (Al 2 O 3 is Particles such as (main component) are mixed with an organic binder such as phenol resin, and molded into a predetermined shape to form a core body. This core body has a bending strength of about 4 to 6 MPa.

Next, a coating layer is formed on the surface of the core body. This coating layer is for preventing the molten metal from penetrating into the core body. The presence of the coating layer makes it possible to prevent the cast product and the core body from becoming difficult to separate from each other and to prevent the cast product from being rough.

Various studies have been conducted on the material of the coating layer. For example, Japanese Patent Publication No. 57-59013
In the publication, a first layer obtained by drying and solidifying a first slurry containing a powdered refractory and a water-soluble thermosetting resin and having a pH and a viscosity adjusted by a water glass aqueous solution,
It has been proposed to use a second layer obtained by drying and solidifying a second slurry containing mica etc. as a coating layer (hereinafter, referred to as prior art 1).

If the coating layer is too strong, it will be difficult to break down the sand core. In other words, the collapsibility of the sand core is reduced. Therefore,
In Conventional Technique 1, the amount of organic binder in the core body is 2.95.
It is made to be less than the usual amount by weight% so that the core body can be easily collapsed.

In Japanese Patent Publication No. 3-36614,
First, a first layer containing no organic binder is formed, and then the first layer is formed.
It has been proposed to maintain the disintegration property of the sand core by applying a low-temperature decomposable resin on the layer and then forming a second layer containing scaly graphite or mica (hereinafter, referred to as prior art). Two
That).

[0008]

However, in the above-mentioned prior art 1, when the molten metal is introduced into the cavity, the second layer may be separated from the first layer. When such a situation occurs, a portion corresponding to a portion where the second layer is separated in the cast product projects, so that the dimensional accuracy is deteriorated. Further, since the water glass contained in the first layer reacts with the molten aluminum, and as a result, a composite layer of the first layer and aluminum is generated, it is difficult to separate the cast product from the sand core. Invite.

Further, as described above, in Conventional Technique 1, since the amount of the organic binder is small, cracks are likely to occur in the core body. For this reason, if a crack exists at the position where the second layer is separated, it becomes difficult for the cast product and the sand core to separate when the molten metal is cooled and solidified with the molten metal inserted in the crack.

After all, in the prior art 1, when the second layer is separated from the first layer, the dimensional accuracy of the cast product is lowered and
It becomes difficult to remove the cast product from the sand core.

On the other hand, in the prior art 2, since the first layer does not contain the organic binder, the first layer and the core body may not be bonded with sufficient force. For this reason, cracks are likely to occur in the core body.
There is a problem that the molten metal is easy to insert and the cast product and the sand core are difficult to separate.

The present invention has been made in order to solve the above-mentioned problems, and it is possible to prevent the molten metal from being inserted, and for this reason, it is possible to obtain a cast product having excellent dimensional accuracy. An object is to provide a sand core and a method for producing the same.

[0013]

In order to achieve the above object, the present invention comprises a core body composed of aggregate particles bonded together by a binder, and a powdery refractory material. A coating layer for covering the surface of the main body, wherein a part of the coating layer is embedded in the pores of the core body and is coupled to the core body.

As the coating layer is buried in the core body, the pores existing near the surface of the core body are closed. Therefore, the molten metal is remarkably suppressed from permeating the core body during the casting operation. In other words, it is possible to prevent the molten metal from being inserted into the core body, so that it is possible to obtain a cast product with good dimensional accuracy and less rough skin.

Moreover, since the molten metal does not enter the core body, the cast product can be easily separated from the sand core.

Here, it is preferable that particles having different average particle diameters are mixed as the powdery refractory. In this case, the pores existing in the vicinity of the surface of the core body can be surely filled with the particles having a small particle size. On the other hand, it becomes possible to form a coating layer on the surface of the core body, mainly with a large particle size.

The sand core for casting is preferably one in which a second layer containing a lubricity imparting substance is provided on the coating layer. This is because the presence of this second layer makes it easier to separate the cast product from the sand core.

A preferred example of the lubricity-imparting substance is mica.

Further, the core body preferably contains a composite oxide of aluminum oxide and silicon oxide as a constituent material. The coefficient of thermal expansion of this composite oxide is extremely small. For this reason, since the core body is unlikely to undergo thermal expansion, the internal stress generated in the core body due to the thermal expansion is significantly reduced. Therefore, it is possible to avoid the occurrence of cracks in the core body, and ultimately to further improve the dimensional accuracy of the cast product.

The present invention also provides a first step of preparing a coating layer slurry containing a powdered refractory material and an organic binder, and allowing the coating layer slurry to penetrate into the pores of the core body and the core. It is characterized by including a second step of laminating on the surface of the main body, and a third step of drying and solidifying the coating layer slurry to form a coating layer.

According to such a manufacturing method, the coating layer slurry permeates the core body to fill the pores existing in the vicinity of the surface of the core body, and then the remaining coating layer slurry is filled with the core body. Laminate on the surface of. For this reason,
It is possible to reliably obtain the coating layer, a part of which is buried in the core body.

In this case, it is preferable to prepare and use a coating layer slurry in which powdery refractories having different average particle diameters are blended. The pores can be reliably blocked mainly by those with a small particle size, and the slurry with a large particle size, which is difficult to flow into the pores, is left on the surface of the core body to form a coating layer slurry. This is because layers can be provided.

In the case of providing the second layer for facilitating the separation of the cast product, in addition to the above first to third steps, a fourth step of preparing a slurry for the second layer containing a lubricity imparting substance, A fifth step of stacking the second layer slurry on the coating layer and a sixth step of drying and solidifying the second layer slurry to form a second layer may be performed. Note that mica can be used as the lubricity imparting substance.

It is preferable to add a wetting agent and a defoaming agent to the coating layer slurry and the second layer slurry. The slurry containing the wetting agent has improved wettability. That is, for example, the coating layer slurry,
Spreads and adheres to the surface of the core body. Therefore, it is possible to reliably form the layer made of the slurry for the coating layer, and further the coating layer, on the surface of the core body. The same applies to the second layer slurry. The defoaming agent suppresses the generation of bubbles due to the addition of the wetting agent.

It is preferable that octyl alcohol is further added to the coating layer slurry and the second layer slurry. If octyl alcohol is present,
This is because the thickness of the finally formed layer will be substantially uniform.

[0026]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of a sand core for casting and a method for manufacturing the same according to the present invention will be described below in detail with reference to the accompanying drawings.

The sand core for casting according to the present embodiment (hereinafter,
A schematic overall perspective view of a sand core) is shown in FIG.
The sand core 10 is used when a cylinder block (not shown) that constitutes an internal combustion engine mounted on an automobile body is manufactured as a cast product, and the hollow core formed by the sand core 10 in the cylinder block. The section serves as a water jacket section.

FIG. 2 is an enlarged cross-sectional view of the sand core 10 near the surface thereof. As is clear from FIG. 2, the sand core 10 has a three-layer structure in which the first coating layer 14 and the second coating layer 16 are laminated in this order on the surface of the core body 12. In FIG. 2, reference numeral 1
8 indicates closed pores that remained without being filled with the first coating layer 14.

In this case, the core body 12 is formed by bonding the cerabead particles 20 with a phenol resin (not shown). Here, Cera beads is a trade name of artificial sand sold by ITOCHU CERATECH CORPORATION, and contains about 98% of a composite oxide of SiO 2 and Al 2 O 3 .

Cela beads have a remarkably small coefficient of thermal expansion as compared with other general sands for cores such as zircon sand, chromite sand and silica sand. In other words, the core body 12
Does not easily cause thermal expansion even when molten metal is introduced. Therefore, the occurrence of cracks in the core body 12 is suppressed.

The bending strength of the core body 12 is about 20M.
Pa is relatively high.

The lower part of the first coating layer 14 is buried in the core body 12. As will be described later, such a state can be achieved by filling the pores of the core body 12 with the first slurry that becomes the first coating layer 14 and then cooling and solidifying the first slurry. The burial depth D of about 0.5 mm is sufficient.

The first coating layer 14 is formed by binding zircon flour as a powdery refractory material to each other with a phenolic resin (organic binder). In this case, zircon flours having different average particle diameters are blended. In particular,
A large particle size zircon flour having an average particle size of about 10 μm and a small particle size zircon flower having an average particle size of about 1 μm. Water glass is not contained in the first coating layer 14.

The distance H from the surface of the core body 12 to the upper end surface of the first coating layer 14 is such that the molten metal can be prevented from being inserted into the core body 12 and the collapsibility of the sand core 10 is not deteriorated. Is set. Specifically, 0.1-
It is preferably within the range of 0.3 mm. In the following description, the distance H from the surface of the core body 12 to the upper end surface of the first coating layer 14 is defined as the first coating layer 14
Of thickness H.

The second coating layer 16 contains mica as a lubricity imparting substance. As will be described later, the presence of mica allows the cylinder block to be easily separated from the sand core 10. The second coating layer 16 preferably contains an organic binder such as a phenolic resin. This is because the second coating layer 16 is firmly bonded to the first coating layer 14 and eventually the second coating layer 16 is less likely to peel off.

The thickness T of the second coating layer 16 may be such that it provides sufficient lubricity so that the cylinder block can be easily removed from the sand core 10.
For example, it can be about 0.1 mm. in this case,
Since the first coating layer 14 has few pores, the second coating layer 16 is not buried in the first coating layer 14.

The sand core 10 according to the present embodiment is basically constructed as described above. Next, its function and effect will be described.

When the cylinder block is manufactured by the die casting method, after placing the sand core 10 in the cavity, the mold is closed. Then, the molten aluminum at about 600 ° C., for example, the pressure is about 100 MPa, the speed is about 2.5 m
/ Sec into the cavity.

As described above, the core body 12 is covered with the first coating layer 14 and the second coating layer 16. Of these, the first coating layer 14
Has a lower part buried in the core body 12, so that the core body 12 and the core body 12 are firmly coupled to each other. Therefore, the first
The coating layer 14 does not flow out together with the second coating layer 16 by the high-pressure and high-speed molten metal.

Moreover, the lower portion of the first coating layer 14 is filled with the pores existing in the vicinity of the surface of the core body 12 and buried therein. That is, the pores near the surface of the core body 12 are closed by the first coating layer 14. For this reason, the molten metal is suppressed from penetrating into the core body 12, so that the molten metal does not eventually flow into the pores existing inside the core body 12.

Further, in the present embodiment, the core body 12
Cera beads having an extremely small coefficient of thermal expansion are used as the constituent material of the. In other words, since the thermal expansion amount of the core body 12 is extremely small, the internal stress generated in the core body 12 due to the thermal expansion is also extremely small. Therefore, the core body 1
It is possible to avoid the occurrence of cracks in the second coating layer 14, the first coating layer 14, and the second coating layer 16.

That is, in the present embodiment, the first coating layer 14 which is hard to wash off closes the pores existing in the vicinity of the surface of the core body 12 and the core body 12 is not easily cracked, so that the molten metal The insertion into the core body 12 can be reliably avoided. Therefore, it is possible to obtain a cylinder block that is a cast product with high dimensional accuracy, and it is possible to prevent the cylinder block from being roughened.

After the introduction of the molten metal into the cavity is completed,
The molten metal is left to stand for a predetermined time to cool and solidify. Then, the cylinder block together with the sand core 10 is taken out from the cavity, and then the cylinder block is easily separated from the sand core 10. Specifically, the sand core 10 is disintegrated by a known technique such as a water jet method or a blast method. At this time, since the first coating layer 14 is provided with an appropriate thickness H, the sand core 10 is not prevented from collapsing.

Then, as described above, the molten metal is sand core 1
Since the insertion into 0 is suppressed, the cylinder block inevitably having no portion inserted into the sand core 10 is obtained. Further, since the first coating layer 14 does not contain water glass, the aluminum and water glass do not react with each other to form a composite layer. Therefore, the cylinder block can be easily separated from the sand core 10.

Moreover, the second coating layer 16 contains mica which imparts lubricity. Therefore, when the cylinder block is removed from the sand core 10, the sand core 1
The frictional force between 0 and the cylinder block becomes extremely small. That is, the cylinder block can be more easily removed from the sand core 10.

The sand core 10 can be manufactured as follows.

FIG. 3 shows a flowchart of the method for manufacturing the sand core 10 according to this embodiment. This manufacturing method is the first
A first step S1 of preparing a coating layer slurry (hereinafter referred to as a first slurry), a second step S2 of infiltrating and stacking the first slurry in the core body 12, and a first step of drying and solidifying the first slurry. A third step S3 for forming the first coating layer 14, a fourth step S4 for preparing a second coating layer slurry (hereinafter referred to as a second slurry),
A fifth step S5 of stacking the second slurry on the first coating layer 14 and a second step of drying and solidifying the second slurry
And a sixth step S6 of forming the coating layer 16.

First, in the first step S1, a first slurry is prepared. That is, a large particle size zircon flour having an average particle size of about 10 μm, a small particle size zircon flour of about 1 μm, a phenolic resin, a wetting agent, an antifoaming agent and octyl alcohol are mixed with water. At the time of this blending, generation of bubbles due to the wetting agent is suppressed by the action of the defoaming agent.

Then, in the second step S2, the first step
The slurry is permeated into the core body 12 and laminated on the surface of the core body 12. Specifically, the core body 1
2 may be immersed in the first slurry. The immersion time is such that the thickness H when the first slurry sufficiently penetrates the core body 12 and becomes the first coating layer 14 is 0.1.
It may be set according to the viscosity of the first slurry so that the first slurry is laminated with a thickness of about 0.3 mm.

At this time, the small particle size zircon flour contained in the first slurry mainly flows into the pores of the core body 12. Therefore, it is possible to fill the pores with a high filling rate. On the other hand, most of the large particle size zircon flour does not flow into the pores and is laminated on the surface of the core body 12. Since the first slurry has good wettability due to the wetting agent contained in the first slurry, the sand core 1
It adheres well to the 0 surface. In addition, due to the action of octyl alcohol, the laminated thickness becomes substantially uniform. That is, octyl alcohol is a flattening agent that makes the laminated thickness of the first slurry and thus the thickness H of the first coating layer 14 substantially uniform.

As described above, by using the first slurry containing the powdered refractory having different particle diameters, the pores of the core body 12 can be filled and the first core body 12 has a first surface. A layer of slurry can be formed.

After the core body 12 is immersed in the first slurry for a predetermined time, the core body 12 is taken out and the
In step S3, the first slurry is dried and solidified to form the first coating layer 14 having a thickness H of about 0.1 to 0.3 mm. At this time, the powdery refractory is bonded to each other by the phenolic resin, and the core body 12 and the first coating layer 14 are firmly bonded to each other.

While performing the above first to third steps S1 to S3, the second slurry is prepared in the fourth step S4. That is, mica, lubricate (lubricant), wetting agent, defoaming agent and octyl alcohol are blended together with water. If necessary, an organic binder such as a phenolic resin may be further blended.

Then, in the fifth step S5, the second step
The slurry is laminated on the first coating layer 14. This lamination can also be performed by immersing the core body 12 on which the first coating layer 14 is formed in the second slurry. Alternatively, the second slurry may be laminated by various coating methods such as a spray coating method and a brush coating method.

Then, in the sixth step S6, if the second slurry is dried and solidified, the first coating layer 14 and the second coating layer 16 are laminated in this order on the surface of the core body 12 in the sand. The child 10 is obtained.

In the present embodiment, the second coating layer 16 is provided over the entire surface of the first coating layer 14, but it is not necessary to provide it over the entire surface. For example, it may be formed only in a portion that is difficult to separate from the cylinder block. Thus, the second
By partially providing the coating layer 16, the manufacturing cost of the sand core 10 can be reduced. In this case, in the fifth step S5, the second slurry may be applied only to the places where the second coating layer 16 is provided.

If the cylinder block can be easily detached without forming the second coating layer 16, it is not necessary to provide the second coating layer 16 in particular.

Further, in the present embodiment, the cylinder block is exemplified as the cast product, but it is needless to say that the present invention is not particularly limited to this.

[0059]

As described above, according to the sand core for casting according to the present invention, the first coating layer is buried in the core body, which closes the pores near the surface of the core body. Has been done. Therefore, it is possible to prevent the molten metal from being inserted into the core body, and therefore, it is possible to obtain an effect that a cast product having good dimensional accuracy and less rough skin can be obtained.

Further, according to the method for manufacturing a sand core for casting according to the present invention, the first slurry as the first coating layer permeates the core body to fill the pores near the surface, and
The slurry is laminated on the surface of the core body. Therefore, it is possible to reliably obtain the first coating layer, a part of which is buried in the core body.

[Brief description of drawings]

FIG. 1 is a schematic overall perspective view of a sand core for casting according to the present embodiment.

FIG. 2 is an enlarged cross-sectional view of the vicinity of the surface of the sand core for casting shown in FIG.

FIG. 3 is a flowchart of a sand core for casting according to the present embodiment.

[Explanation of symbols]

10 ... Sand core 12 ... Core body 14 ... First coating layer 16 ... Second coating layer 18 ... Closed pores 20 ... Particles

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Shigemitsu Nakabayashi             1-10-1 Shinsayama, Sayama City, Saitama Prefecture             Engineering Co., Ltd. (72) Inventor Atsushi Suzuki             1-10-1 Shinsayama, Sayama City, Saitama Prefecture             Engineering Co., Ltd. F-term (reference) 4E092 AA01 AA03 AA04 AA23 AA36                       AA45 BA03 BA11 CA01 FA10                 4E093 QA01 QA10 QC10 UA02

Claims (11)

[Claims]
1. A core body comprising aggregate particles bonded together by a binder, and a coating layer containing a powdered refractory and coating the surface of the core body. The sand core for casting is characterized in that the part is connected to the core body while being buried in the pores of the core body.
2. The sand core for casting according to claim 1, wherein the powdery refractory material is a mixture of particles having different average particle sizes.
3. The casting sand core according to claim 1, further comprising a second layer provided on the coating layer and containing a lubricity imparting substance. .
4. The sand core for casting according to claim 3, wherein the lubricity imparting substance is mica.
5. The sand core for casting according to claim 1, wherein the core body contains a composite oxide of aluminum oxide and silicon oxide as a constituent material. Sand core for casting.
6. A first step of preparing a coating layer slurry containing a powdered refractory and an organic binder, and allowing the coating layer slurry to permeate into the pores of the core body and onto the surface of the core body. A second step of stacking, and a third step of drying and solidifying the coating layer slurry to form a coating layer, the method for producing a sand core for casting.
7. The method for producing a sand core for casting according to claim 6, wherein powdery refractories having different average particle sizes are mixed to prepare the slurry for the coating layer.
8. The manufacturing method according to claim 6, further comprising a fourth step of preparing a second layer slurry containing a lubricity imparting substance, and the second layer slurry on the coating layer. A fifth step of laminating, and a sixth step of drying and solidifying the second layer slurry to form a second layer, the method for producing a sand core for casting.
9. The method for manufacturing a sand core for casting according to claim 8, wherein mica is used as the lubricity imparting substance.
10. The manufacturing method according to claim 6, wherein a wetting agent and a defoaming agent are added to the coating layer slurry and the second layer slurry. Manufacturing method of sand core for casting.
11. The casting method according to any one of claims 6 to 10, wherein octyl alcohol is further added to the coating layer slurry and the second layer slurry. Sand core manufacturing method.
JP2001393901A 2001-12-26 2001-12-26 Sand core for casting and method for producing the same Expired - Fee Related JP3581687B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
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Publications (2)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2364795A1 (en) 2010-03-08 2011-09-14 Foseco International Limited Foundry coating composition
CN102343418A (en) * 2011-08-29 2012-02-08 西安西工大超晶科技发展有限责任公司 Casting method of three-dimensional flow aluminum alloy impeller casting
CN105149518A (en) * 2015-10-14 2015-12-16 河北天宇高科冶金铸造有限公司 Sand core and method for casting molding of deep holes with same

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2364795A1 (en) 2010-03-08 2011-09-14 Foseco International Limited Foundry coating composition
WO2011110798A1 (en) 2010-03-08 2011-09-15 Foseco International Limited Foundry coating composition
US20130032689A1 (en) * 2010-03-08 2013-02-07 Foseco International Limited Foundry coating composition
US8778076B2 (en) * 2010-03-08 2014-07-15 Foseco International Limited Foundry coating composition
CN102343418A (en) * 2011-08-29 2012-02-08 西安西工大超晶科技发展有限责任公司 Casting method of three-dimensional flow aluminum alloy impeller casting
CN105149518A (en) * 2015-10-14 2015-12-16 河北天宇高科冶金铸造有限公司 Sand core and method for casting molding of deep holes with same

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