The Cosworth process is a precision sand casting process, which was developed in 1978 for non-ferrous casting, initially aluminium alloys, to engineer the Cosworth engine. The mould and core-making stages are similar to conventional sand casting, although zircon sand is used instead of silicon, due to its greater expansion predictability. The main feature of this process is that the metal is pumped into the mould through the base using pressure assisted feeding through a simplified gating system.



The absence of conventional gating and feeding systems results in castings free of porosity (due to hydrogen) and inclusions (due to alumina). These are common in sand and gravity die casting and impair the metallurgical integrity and mechanical properties of the casting. The process also eliminates a number of minor problems associated with conventional techniques including: blowholes from chills, cores and adhesives; inaccurately located cores and mould halves; and metallurgical inadequacies (particularly poor hardness or strength). It also reduces fettling time. The process was more recently extended to a number of commercial castings with the opening of a new foundry in 1984. In 1993 the Ford Motor company selected the Cosworth process for its Windsor, Ontario, Plant. The American Foundrymen's Society has identified the Cosworth process as being a key emerging process, needing further investigation to develop commercial opportunities.