Replication of Microscale Features via Investment Casting Using the Example of an Aluminium Intake Manifold of a Gasoline Engine with an Inner Technical Shark Skin Surface

Within the project “Functional Surfaces via Micro- and Nanoscaled Structures” an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1µm on near-net-shape-casting parts will be developed. The common way to realise functional microscale features on metallic surfaces is to use laser ablation, electro discharge machining or micro milling. The handicap of these processes is their limited productivity. In order to raise the efficiency, microscale features will be replicated by use of the investment casting process. The main research objective deals with the investigation of the single process steps with regard to the moulding accuracy. Actual results concerning making of the wax pattern and the ceramic mould as well as the casting of an Aluminium alloy will be presented. By using the example of an intake manifold of a gasoline race car engine a technical shark skin surface was defined in order to reduce the drag of the in-coming air. Possible process stategies to realise microscale features on an inner surface of a casting part were developed.