When you have to cast an intricate metal part meant to last a long period of time under immense forces, you can’t just come and pour the molten material into the mould hoping that everything is gonna be fine.
No, there are special rules for casting such items, like Lexus’ aluminum engine blocks. One of the most important rule is to make sure there are no air bubbles forming in the mould.
Just like when you turn water into a glass, the liquid will start splashing all over the place, forming air bubbles. But while in a glass of water they tend to disappear fast, there is another story with them in a moulding during the casting process. The air bubbles tend to remain stuck in the material as it cools down and they represent a real threat to the structural integrity of the whole piece.
That’s why Lexus uses a special technique to cast its cylinder blocks, which you can see in the video bellow.
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