Method for manufacturing an aluminum die cast piston for reciprocating compressors

1. A piston for a reciprocating compressor, comprising:

a die cast aluminum body having a head at a first end and a cylindrical contour forming an exterior boundary extending away from the head to an opposed second end, the body having a preselected outer diameter, a preselected inner geometry and a preselected thickness so as to form a cavity within the body having walls for receiving a rod, the head, the outer diameter and the inner geometry of the body forming a continuous wall, the cavity having an opening adjacent to the opposed second end of the body, the piston further characterized by an absence of apertures formed by coring extending diametrally through the walls;

the walls having a preselected geometry forming an interior boundary of the body within the cavity;

the piston capable of receiving at least one aperture extending diametrally across and through the outer diameter of the piston at a preselected location between the first end and the second end, the aperture having a preselected diameter corresponding to an outer diameter of a pin; and

wherein the walls having a preselected geometry include a first pair of substantially parallel walls extending as chords across the cavity; and a second pair of substantially parallel walls, the second pair of walls extending as chords across the cavity substantially at about 90° to the first pair of walls, the first and second pair of walls forming a substantially rectangular geometry within the cavity of the piston.

2. The piston of claim 1 further including a machined aperture extending diametrally across and through the outer diameter of the piston at a preselected location between the first end and the second end.

3. The piston of claim 1 wherein the walls having a preselected geometry include a geometry preselected to accept a predetermined geometry of a first end of a connecting rod.

4. A method for producing a die cast aluminum alloy piston for a reciprocating compressor comprising the steps of:

casting an aluminum piston having a head at a first end and a cylindrical body extending away from the head to a second end opposed to the head, the body having a preselected outer diameter, a preselected inner geometry and a preselected thickness so as to form a shell, the head and the inner geometry of the cylindrical body defining a cavity opening to the second end opposed to the head, the cast piston further characterized by an absence of a core-formed aperture extending diametrally through the shell, a first pair of parallel rectangular walls extending as chords across the cavity and a second pair of parallel rectangular walls extending as chords across the cavity substantially at about 90° to the first pair of rectangular walls, the first and second pair of rectangular walls forming a substantially rectangular geometry within the cavity; then

forming at least one aperture extending diametrally across and through the shell of the cast piston at a preselected location between the first end and the second end, the aperture having a preselected diameter corresponding to an outer diameter of a pin so as to receive the pin.

5. The method of claim 4 further including forming a pair of apertures substantially at right angles to one of the pair of rectangular walls.

6. The method of claim 5 wherein the apertures are formed substantially at right angles to the longer pair of rectangular walls.

7. The method of claim 6 wherein the step of forming the aperture after casting the piston includes machining the aperture diametrally through the walls at a preselected location between the first end and the second end.

8. The method of claim 6 wherein the step of forming the aperture after casting the piston further includes forming apertures of preselected diameter so as to receive the pin.

9. The method of claim 4 wherein the step of casting an aluminum piston further includes an aluminum alloy selected from the group consisting of Al-A380, Al-A383, Al-A390 and Al-A356.