Method of making a forged piston with an oil gallery

Claim 1

A METHOD OF MANUFACTURING AN INTERNAL COMBUSTION ENGINE PISTON COMPRISING: FORMING AN ALUMINUM ALLOY PISTON SLUG CONSISTING OF BY WEIGHT 10.5-11.5 SILICON, 0.5-0.9 PERCENT MAGNESIUM, 1.5-2.0 PERCENT COPPER, 0.4-0.9 PERCENT MANGANESE, NO GREATER THAN 0.7 PERCENT IRON, NO GREATER THAN 0.4 PERCENT ZINC, AND THE REMAINDER BEING ALUMINUM, FORMING A PREFORM WITH SAID SLUG HAVING A GREATER VOLUME OF STOCK NEAR THE OUTER DIAMETER OF THE PORTION THAT FORMS A PISTON HEAD, FORGING THE PREFORM AND FORMING A FORGED PISTON BLANK HAVING A PISTON HEAD PORTION WITH A FRUSTO-CONICAL RIDGE AXIALLY OUTWARDLY EXTENDING FROM THE TOP WALL OF SAID PISTON HEAD AROUND THE PERIPHERY THEREOF AND AN ANNULAR AXIAL BLANK GROOVE CONCENTRIC WITH AND EXTENDING AXIALLY INWARDLY FROM THE END OF THE RIDGE AND A PREDETERMINED DISTANCE INTO THE PISTON HEAD AND HAVING A CLOSED GROOVE END, SIZING SAID FRUSTO-CONICAL RIDGE TO HAVE A VOLUME SUBSTANTIALLY EQUAL TO THE VOLUME NECESSARY TO CLOSE SAID ANNULAR GROOVE AND PROVIDE A SUBSTANTIALLY FLAT PISTON HEAD TOP WALL AND AN OIL GALLERY CAVITY IN THE PISTON HEAD, SIZING A TUBULAR FORM RING TO HAVE A VOLUME EQUAL TO THE VOLUME OF THE OIL GALLERY AND A THICKNESS EQUAL TO THE THICKNESS OF THE ANNULAR GROOVE. SAID FORM RING BEING A ZINC ALLOY HAVING A MELTING TEMPERATURE OF 700-900* F. AND HAVING A REFRACTORY MOLD WASH COATING THEREON COMPRISING SILICA FLOUR WITH A SODIUM SILICATE BINDER, HEATING SAID FORGED PISTON BLANK TO TEMPERATURES OF 750-950* F., IN A MAXIMUM OF TWO MINUTES INSERTING THE TUBULAR FORM RING IN THE ANNULAR GROOVE, AND UPSETTING THE FORGED PISTON RIDGE TO CLOSE THE ANNULAR GROOVE TO PROVIDE A SUBSTANTIALLY FLAT PISTON HEAD TOP WALL WITH AN ANNULAR WELD V-GROOVE THEREIN CONCENTRIC WITH THE FORM RING AND MAINTAINING CONSTANT PISTON HEAD AND FORM RING VOLUMES, DRILLING A PLURALITY OF CIRCULAR HOLES THROUGH THE BOTTOM WALL OF THE PISTON HEAD TO COMMUNICATE WITH THE FORM RING, SOLUTION TREATING THE PISTON FOR TWO TO FOUR HOURS AT TEMPERATURES OF 940-1000* F., WATER QUENCHING THE SOLUTION TREATED PISTON,

Claim 2

A METHOD OF MANUFACTURING AN INTERNAL COMBUSTION ENGINE PISTON COMPRISING: FORMING AN ALUMINUM ALLOY PISTON SLUG CONSISTING OF BY WEIGHT 10.5-11.5 SILICON, 0.5-0.9 PERCENT MAGNESIUM, 1.5-2.0 PERCENT COPPER, 0.4-0.9 PERCENT MANGANESE, NO GREATER THAN 0.7 PERCENT IRON, NO GREATER THAN 0.4 PERCENT ZINC, AND THE REMAINDER BEING ALUMINUM, FORMING A PREFORM WITH SAID SLUG HAVING A GREATER VOLUME OF STOCK NEAR THE OUTER DIAMETER OF THE PORTION THAT FORMS A PISTON HEAD, FORGING THE PREFORM AND FORMING A FORGED PISTON BLANK HAVING A PISTON HEAD PORTION WITH A FRUSTO-CONICAL RIDGE AXIALLY OUTWARDLY EXTENDING FROM THE TOP WALL OF SAID PISTON HEAD AROUND THE PERIPHERY THEREOF AND AN ANNULAR AXIAL BLANK GROOVE CONCENTRIC WITH AND EXTENDING AXIALLY INWARDLY FROM THE END OF THE RIDGE AND A PREDETERMINED DISTANCE INTO THE PISTON HEAD AND HAVING A CLOSED GROOVE END, SIZING SAID FRUSTO-CONICAL RIDGE TO HAVE A VOLUME SUBSTANTIALLY EQUAL TO THE VOLUME NECESSARY TO CLOSE SAID ANNULAR GROOVE AND PROVIDE A SUBSTANTIALLY FLAT PISTON HEAD TOP WALL AND AN OIL GALLERY CAVITY IN THE PISTON HEAD, SIZING A TUBULAR FORM RING TO HAVE A VOLUME EQUAL TO THE VOLUME OF THE OIL GALLERY AND A THICKNESS EQUAL TO THE THICKNESS OF THE ANNULAR GROOVE. SAID FORM RING BEING A ZINC ALLOY HAVING A MELTING TEMPERATURE OF 700-900* F. AND HAVING A REFRACTORY MOLD WASH COATING THEREON COMPRISING SILICA FLOUR WITH A SODIUM SILICATE BINDER, HEATING SAID FORGED PISTON BLANK TO TEMPERATURES OF 750-950* F., IN A MAXIMUM OF TWO MINUTES INSERTING THE TUBULAR FORM RING IN THE ANNULAR GROOVE, AND UPSETTING THE FORGED PISTON RIDGE TO CLOSE THE ANNULAR GROOVE TO PROVIDE A SUBSTANTIALLY FLAT PISTON HEAD TOP WALL WITH AN ANNULAR WELD V-GROOVE THEREIN CONCENTRIC WITH THE FORM RING AND MAINTAINING CONSTANT PISTON HEAD AND FORM RING VOLUMES, DRILLING A PLURALITY OF CIRCULAR HOLES THROUGH THE BOTTOM WALL OF THE PISTON HEAD TO COMMUNICATE WITH THE FORM RING, SOLUTION TREATING THE PISTON FOR TWO TO FOUR HOURS AT TEMPERATURES OF 940-1000* F., WATER QUENCHING THE SOLUTION TREATED PISTON,