cast products 2 (1)

7/23/2019 Cast Products 2 (1)

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Engine block of a 500 cc motorcycle

• Process typeDirect Shell Production CastingMaterial usedA35 ! aluminumProduct and material re"uirements and specialties!ypical re"uirements in#ol#ed in high performance enginemanufacture like high strength$ strict tolerance etc%%%



Cellular phone keypad and

display enclosures



Cellular phone keypad and display enclosures

• Process type !hi&otropic molding

• Material used AZ-91D magnesium alloy• Product and material re"uirements and specialties

• The component’s walls are between 0.8 an 1.0 mm thic!" with a total casting weight o# 10$ grams.

• Process re"uirements and specialties and specialties

• %apability o# accurately casting the small etails in&ol&e an economical large scale prouction

• Process Details

• This component was cast by in'ecting semi-soli state magnesium into a close ie in a similar mannerto plastic in'ection moling.

• Problems Encountered% (A

• Process ad#antages

1. )mpro&e rigiity an impact resistance an impact resistance o&er pre&ious plastic in'ection molingmanu#acture

*. %apability o# pro&iing electro-magnetic inter#erence shieling without e+ternal coatings or plating.



•

Component' (%5 meter #al#e for a municipal )ater )orks• Material'*o lead brass Process' +reen sand



Cast Component' Steering column upper bearing assembly for Mitsubishi%

Material'Aluminum% Process' Diecasting%



Air intakemanifold for4 cylinder

engine

http://www.nuovafondal.it/images/coll4_big.jpg



,ce cutter used in an industrial ice machine%

• Process type )n&estment casting.

• Material used ,1 stainless steel.

• Product and material re"uirements andspecialties

• igh rigiity an harness

• Process re"uirements and specialties

• (o warping an stress concentrations to bee&elope.

• Process Details

1. An in&estment precoat was applie to increasethe sur#ace smoothness o# the pattern.

*. The e+penable pattern was surroune by are#ractory slurry

,. /achining to speci#ications

. olution annealing



(% ,nfrared Microscope -rameProcess type .acuum molding

Material used A35/! aluminum alloy

Product and material re"uirements and specialties

!he )eight of the product is to be minimum%!he product should be sufficiently rigid to a#oid any errors%

Process re"uirements and specialties and specialties

all thickness should not be greater than 0%1 in any)here in

the casting% So draft should be minimum%

Machining of the #arious small parts that are present should

be minimum to reduce cost%

!olerance of the order of 20%0(5/0%010 in%

Process Details

A heater softens a thin plastic that drapes o#er a pattern on a

hollo) carrier plate%

A #acuum then dra)s the film tightly around the pattern and aflask is placed on the pattern to prepare it for the back fill of

sand%

!he sand is compacted$ the back of the mold is co#ered )ith a

plastic film and a #acuum is applied to the flask

Atmospheric pressure hardens the mold$ preparing it for the

pouring of metal%



Pistol frame for Smith esson%

• Process type Die/casting%

• Material used A340 aluminum alloy%

• Product and material re"uirements

and specialties


and specialties

• -irst instance of manufacturing of

the gun frame by die casting%

Capability of economically

producing large "uantities%



ocker arm for 6M engines

• Process type %ounter gra&ity in&estment casting

• Material used %arbon steel.

• Product and material re"uirements and specialties

As the camsha#t rpm increases" the roc!er arms run #aster an hotter. Thesecomponents must withstan the temperatures an pressure o# engine operation.


Zero sur#ace e#ects

Ability to hanle e+tremely large prouction &olume.

• Process Details

%eramic mols are manu#acture #rom wa+ patterns

The mols are in&erte an then #ille with molten metal2&ia pressure3 #rom the bottom to the top.



. cylinder block for a 3%7 liter

automobile engine

• Process type Cos)orth precision sand casting%

• Material used% 3(7 aluminum alloy%


• 8sual re"uirements of cylinder block like e&act tolerance$ rigidity etc%

• Process Details

(% A cast/in cylinder liner process is used% Cores for the molding process are made of

9ircon sand :)hich has superior thermal characteristics; to minimi9e machine stock

and re"uired )all thickness%

1% Core oil galleries are as/cast$ re"uiring no internal machining and minimal )all

thickness% !he Cos)orth casting process utili9es a rollo#er casting techni"ue that

impro#es casting yield for the block to <1=$ reducing component cost for thecustomer%



,nternal ,nterface -rame for >CD Digital Pro?ecto

• Process re"uirements and specialties and specialties(% Ability to achie#e comple& thin )all shape and precision features )ith typical post/machine tolerances of @/0%( mm% B *ear/net shape forming to minimi9e machining operations and cost% B Capability of production rates up to 40$000 units per year

• Process Details

(% An S>A resin model is made from the CAD file%

1% A silicon master mold is made from this resin model%

3% A reusable urethane model is made from the abo#e mold%

% ,ndi#idual cope and drag molds are made%

5% Metal is poured into the mold and allo)ed to solidify

% Sprue and riser is cut off:Due to near net casting no ma?or machining operation is necessary;

<% ,nspection and shipping

• Process Ad#antages

(% ,mpro#ed rigidity

1% educed component cost

•Process type Plaster mold )ith rapid prototyping

•Material used Magnesium

•Product and material re"uirements andspecialties

(%>o) )eight B igh structural stiffness and lo)thermal e&pansion to maintain componentalignment B igh thermal conducti#ity and highheat tolerance :>ocal temperatures as high as

150C%;



6ull gear for rotating large

platforms in the oil industry

• Process type

• Material used

• Product and materialre"uirements and specialties

• A high/strength alloy steel perAS!M/A/(4$ +rade ((575 )ith

• minimum ((5$000/psi ultimatetensile strength

• 75$000/psi yield strength

• = elongation• 30= reduction of area

• diameter of 1 ft%

• 554 teeth$ 0%<5 DP stub teeth%



4567 %6

• Process type• Solid imaging

• Material used% *A

• Product and materialre"uirements and specialties

• adical design o#ercon#entional golf clubsF

• Process re"uirements andspecialties

• Manufacture of t)o sets of ironsfrom design in ( )eek

ContinuedG%%



4567 %6- :rocess Details

• Actua *100 #rom ,D ystems was chosen as the soli imaging e&ice.

• The printer trans#orms %AD ieas;li!e the gol# clubs;into physical realityusing soli imaging technology. . )t uses an approach similar to in! 'et

printing" but the 'ets ispense a plastic-li!e material to create the soli moel.)t uses this plastic-li!e material to create wa+ patterns with &ery thin wallsan intricate unercut geometry. )n aition" the spee o# the printer ma!es it

possible to prouce esigns in one ay" allowing timely proucte&elopment" testing an creation. The printer also can generate wa+

prototypes that help to match the prototyping system to the prouction

process.• $0 wa+ patterns were create on the printer an sent them to the in&estment

#ounry #or casting an #inishing. )n in&estment casting" a ceramic shell is built aroun a wa+ pattern" which is burne out o# the mol be#ore moltenmetal is poure in.

• :roblems <ncountere

• <+tremely small time #rame ga&e no scope #or process iterations anre#inements.

• :rocess a&antages

• The player who use the gol# clubs prouce won the tournament==



AT/

%ounter

• Process type +ra#ity permanent mold casting

• Material used A30 aluminum


• !amper proof assemblyB +ood aesthetic appearance


• Production figures of up to (00 components)eek$

• !he parting plane on the casting had to be hori9ontal• !he metal feeding system into the mold could not use side feeders

• Process Details

(% edesign of the product from earlier manufacturing process :plastic in?ection; BModeling of the casting using a soft)are named magma softF B Pouring of themolten metal into the permanent mold B !he casting needed to be filled in lessthan (0 sec :to eliminate the possibility of pouring defects; )ith the aid of gra#ityonly B Solidification of the casting )ithin (1/(5 s%

• Problems Encountered

• Mold filling and solidification has to be "uick to a#oid the porosity%B ,n a flat areaof the casting$ porosity could be only minimi9ed and not completely a#oided%

• Process ad#antages

• educed cost o#er pre#ious manufacturing method :plastic molding;B ,mpro#edsurface appearance%

• ,mpro#ed functionality :tamper proof;

H t h d f



Heat exchanger used for a

steam-generation application.• Material:Class 35 gray iron.Process: Noa!e

sand molding.Casting "upplier: #ells$ille%oundry& 'nc.& #ells$ille& (hio.

• The 115-lb, 23-in.-long casting contains sevenrings of 31 fins each. The componentoriginally consisted of seven fabricationselded together to form a contin!o!s ringt!be elded to an end cap and flange.

• The ne one-piece casting design "ith 21#$.25-in.-ide fins% feat!res !niform allthickness and is non-leaking beca!se it hasno eld &oints.

• The casting offers a significant lead timered!ction compared to the previo!sfabrication'assembly, lasts longer andimproves the efficiency of the final prod!cthile providing a significant cost savings tothe c!stomer.



)xle housing for *oodman

+,uipment Corp• .(aterial)*teel.+rocess)

hemically bondedsand.asting *!pplier)ol!mbiana o!ndry o.,

ol!mbiana, hio.• This 3/ 0 11 0 24-in. casting

as originally designed as amachined eldment.

• y converting thecomponent to casting, a 33

cost savings as realied bythe c!stomer d!e to theelimination of the assemblytime for the component.



nvestment asting ed!ces *!b-Assembly Time by 6#, ost by

51• The tab ring liner,

originally designed as 1/separate machined tabs

that ere elded together,as converted to a singleinvestment casting,red!cing s!b-assemblycost by 744.$$ and time by2/ min. +ict!red co!nter-

clockise from top are thering elded onto the sheetmetal t!be, the cast do!blering, the single ring andthe completed assembly.



Manifold for fire-fighting

e,uipment(aterial)/5-45-12 d!ctile iron.

+rocess) 8reen sand casting.

asting *!pplier) 9ersa ron and(achine, *t. +a!l, (innesota.

• This :$-lb manifold asconverted from a stainless steeleldment at a per piece costsavings of 755$.45 "ann!alsavings of 722$,16$ ith 4$$ partvol!me%.

• The tooling payback for thepattern, corebo0es and machinefi0t!res as realied ithin thefirst / eeks of prod!ction



hassis for &oy stick tensioning in anaircraft flight sim!lator for *..T., nc

• .(aterial)A35/-T/ al!min!m alloy.

• +rocess) ;obake sand casting.

• asting *!pplier) <anko Arlington,nc., altimore, (aryland.

• This 14-lb component asconverted from an al!min!meldment at a cost "d!e to red!cedelding and fabrication man-ho!rs%and eight savings.

• (eas!ring 1/ 0 : 0 14 in., thecasting is a simpler design than theeldment ith improved rigidity.



abrication "=eft% asting "ight%

• ast omponent) Annealingf!rnace pedestal for a steel mill.

• (aterial)A*T( A-2:# grade >>heat resistant stainless steel.

• +rocess) ;obake sand casting.

• asting *!pplier) ?ellsvilleo!ndry, ?ellsville, hio.

• This one-piece, 25-lb castingreplaced a stainless steelfabrication at a /# cost savings.

• The cost red!ction is d!e to theelimination of fabrication andassembly man-ho!rs.



Air-ride s!spension arm for b!sesthat s!spends the b!s frame on

the front and rear a0les• .(aterial)6$-55-$/ d!ctile iron.

• +rocess) 8reen sand casting.

• asting *!pplier) <onsco, nc., (t.@oy, +ennsylvania.

• onverted from a steelstamping'fabrication, the 12$-lbcasting provided the c!stomer a5$ total cost savings "incl!dingassembly time%.

• The fo!ndry casts paints and

machines the component, andassembles a s!b-system for thec!stomer. The assemblies areshipped directly to the c!stomersman!fact!ring line



racket for a piston coolingsystem on a railroad locomotive

• .(aterial):53 al!min!m brone.

• +rocess) +ermanent mold casting.

• asting *!pplier) A!rora (etals, =.=.. ">ilernd!stries%, (ontgomery, llinois.

• This $.6-lb component as converted topermanent mold casting to eliminate the leaks

inherent in the previo!s man!fact!ring method. naddition, the conversion realied a cost savings byred!cing man-ho!rs and eliminating heat treatmentas permanent mold casting achieves the reB!iredmechanical properties.

• +ermanent mold casting allos a stainless steelt!be insert to be cast directly into the bracket.

• The casting design and gating system ereengineered !sing solidification modeling, ens!ringa B!ality casting from the first shot.



!el rail ho!singfor fo!r-cylinder,2.$- and 2.2-=passenger carmodels• .(aterial)Al!min!m

• .+rocess) *emi-solid casting.• asting *!pplier) (adison-Cipp orp., (adison, ?isconsin.

• An engine config!ration reB!ired a f!el rail ho!sing capable of ithstanding high levels of impactitho!t fail!re. The c!stomer decided that traditional fabricated braed steel t!be and plasticdesigns o!ld not meet the stringent impact reB!irements and opted for a cast component.

• The c!stomer, first-tier s!pplier and casting and machining component s!pplier orked togetherto develop a casting that met the #$$$-lb crash test load hile keeping costs to a minim!m.

• ncreased dimensional acc!racy of critical feat!res prod!ced close tolerance machining forspecial feat!res and res!lted in leak-free performance itho!t impregnation "this as aided bysemi-solids inherent lo porosity characteristic%.



*earox for aytona Prototypes

• (aterial)35/ al!min!m

• +rocess) ;obake sandasting *!pplier)lson Al!min!m astings, ockford,llinois.

• The 44-lb gearbo0 reB!ires e0tensive machiningafter casting and therefore is prod!ced void,porosity, o0ide and shrink free.

• 35/ al!min!m alloed the fo!ndry to achieve thehigh strength-to-eight ratio necessary ofcomponents for competitive motor sports.

• *and casting and its lo-cost toolingreB!irement alloed for engineeringchanges and B!ick tool modifications as

ell as eleven different components in theprogram to be prod!ced in record time.



Tensioner p!lley for tire man!fact!ring

• (aterial)8ray iron

• +rocess) ;o bake sandasting*!pplier) ?ellsville o!ndry,

?ellsville, hio• This 1#5-lb component is !sed

as a brake that p!ts tension on a4 ft. ide roll of r!bber feedinginto a tire press.

• onverted from a steel

fabrication "to ring b!rn-o!tsith spokes%, the fo!ndryprovided the end-!ser ith a5$ cost savings.



(il pump co$er • (aterial)<!ctile iron

• +rocess) 8reen sandasting• *!pplier) ambridge rass, ambridge,

ntario, anada.

• This #$-lb component, hich holds oilfor a gear drive s!mp p!mp, asconverted from a si0-piece eldment ata 4$ cost red!ction.

• The conversion to casting eliminatedseven man!fact!ring steps for the end-!ser, red!cing material handling. naddition, the elimination of eld &ointseliminated oil leakage problems the

fabrication as e0periencing.



• +rototyping for <irect (etal asting) <ata to astings in 12 ho!rs

Pictured is a prototype sand mold and the resultant aluminum pipe casting produced from it.ne of the h!rdles facing todays fo!ndries as they try togro market share is lead time. !stomers ant sample cast parts today to fitinto their prod!ct designs for form, fit and f!nction. f the fo!ndry cant deliver,then the c!stomer ill t!rn to a fabricator for a B!ick sol!tion.

A b i b k t d i th d i t



A bearing bracket !sed in the drive systemon a self-propelled lan moer

• .(aterial)6/2$ steel alloy.+rocess) nvestment"lost a0% casting.asting *!pplier) *ignicastorp., >artford, ?isconsin.

• This $.:1-lb bearing bracket casting, hich asprevio!sly formed from the assembly of a laser-c!tplate that as elded to a h!b machined from barstock, has the added ability to ad&!st the alignment

and tension of the belts ithin the drive system.• The casting design provided an 63 cost

red!ction, hich eB!als 712./5'component. +art ofthis cost savings is d!e to the simplified end-prod!ct assembly that res!lts from the he0 shapesbeing cast for ad&!stment p!rposes.

• The finished cast component is s!pplied by the

fo!ndry after !ndergoing tapping, boring andplating.

Agric!lt!ral component



Cnotter frame for a hay-baling

machine for ;e >olland• .(aterial)A*T( 642-65 grade 35$

compacted graphite iron "8%.+rocess)8reen sand casting.asting *!pplier).>. *heppard o., nc., >anover,

+ennsylvania.• n the previo!s design, the end-!ser as

e0periencing fail!re "breakage% in thecomponents thin sections d!ring !se.As a res!lt, it as converted to a 8casting to improve strength to 5$,$$$ psi

and d!rability of these sections.• The conversion to 8 and its improved

strength also provided the fo!ndry ithan opport!nity to red!ce the eight ofthe component to 6.#5 lb.Agric!lt!ral component



a/nmo/er gear and axle

• .(aterial)A*T( 6:# grade 2$$-155-$1 a!stempered d!ctileiron.+rocess) 8reen sandcasting.asting *!pplier) Applied+rocess, nc., =ivonia, (ichigan.

•+revio!sly man!fact!red as athree-piece carb!ried steelassembly, the gear and a0le castingas converted to a!stemperedd!ctile iron at a cost savings.

• After a!stempering at the heat treatfacility, the casting is machinedcomplete before shipment to thec!stomer.




Mo/er rac!et.

• (aterial)<!ctile iron.+rocess) 8reensand casting.asting *!pplier)<otson o., nc., (ankato, (innesota.

• The c!stomer e0perienced toleranceinconsistencies beteen fabricatedparts on the original steel eldment,prompting the sitch to a singlecomponent casting.

• The original eldment cost thec!stomer 712'piece to man!fact!re.y converting to d!ctile iron casting,the c!stomer saves 7/$,$$$ ann!ally.

• n addition to casting, the fo!ndry ismachining the part, providing thec!stomer ith a finished appearance.




*hifter fork assembly for acombine transmission

• .(aterial):53 al!min!m brone.+rocess)+ermanent mold casting.asting *!pplier) A!rora

(etals, ==, (ontgomery, llinois.

• This component previo!sly as man!fact!red asa m!lti-part iron assembly. The pict!redassembly consists of to components riveted

together and pinned onto a finished shaft.• The stronger, redesigned cast component

pict!red is created from a stainless steel shaftthat is pre-heated and locked in place in thepermanent mold casting die as liB!id al!min!mbrone is po!red aro!nd it.

• The 1.5-lb finished cast component has a tensilestrength of /5,$$$-#5,$$$ psi and a yield strengthof 25,$$$-2#,$$$ psi. t also red!ces necessarysecondary operations and handling.




A< solid model "top%, *=* polycarbonate pattern "left%, A35/ al!min!m casting "right%.

http://wtec.org/loyola/rp/fh10_05.jpg

http://wtec.org/loyola/rp/fh10_04.jpg



Cam clamp used to secure

ambulance gurnees%

• /aterial> tainless

steel.

• :rocess> )n&estment

casting.

• %asting upplier>

)nepenent teel%astings %o." )nc."

(ew u##alo"

/ichigan.



Mounting bracket for medical

centrifuge%

• Material' C-3M stainless steel%

• Process' ,n#estment casting%

• Casting Supplier' .estshell$

,nc%$ Montreal$ Huebec$

Canada%

•



Duck bill for hite Cap$ >%>%C% to seal

caps on food ?ars%

• /aterial>,16

stainless steel.

• :rocess> )n&estmentcasting.


(orthern :recision

%asting %o." 6a!e

4ene&a" ?isconsin.



7an #rame hub #or 4eneral <lectric’s %7-

-80% engine #or oeing’s aircra#t.

• Process type )n&estment casting.

• Material used Titanium.

• Product and material

re"uirements and specialties

• 6arge imensions2$*-in.ia3

• Process re"uirements and

specialties

• %apability o# hanling the

problems encountere in large

castings



acing car upright

• Material' !itanium 1%

•Process' ,n#estmentcasting%

• Casting Supplier'

Coastcast Corp%$ ancho

Domingue9$ California%



ousing actuator for an engine for

amilton Sundstrand% • /aterial> A*0,

aluminum alloy.

• :rocess> )n&estmentcasting.


%abiran" 6t." @ibbut%abri" )srael.



AA 5/M handheld missile/launching system

Process type

,n#estment casting

Material used A35</! aluminum

Product and material re"uirements

and specialties

Ma&imum )eight reduction to reduceoperator fatigue

Process re"uirements and specialties

eduction of )all thickness as much

as possible:less than 0%0 in )ith

the o#erall dimensions(5 & ( & <%5in;



The 5-lb casting is one-tenth scale of the

vac!!m vessel for the ;ational ompact *tellarator D0periment ";*E% beingdeveloped by the +rinceton +lasma =aboratory and the ak idge ;ational=aboratory as the ne0t generation of f!sion e0periment. The scale model asinvestment cast to determine the feasibility of !sing a casting for a vac!!mvessel ith comple0 geometry.To meet the r!sh timeline "ith the help of b!ycastings.com%, *=* rapid prototyping

techniB!es ere employed to make the complicated a0 patterns from a A<'*T= file in 2F G

• Cast Component' .acuum .essel for thepo)er generation industry

• Material',nconel 15

• Process' ,n#estment Casting

• *!pplier) escast, nc., ?illo!ghby,hio



*D(-+D(A;D;T (=< A*T;8

"emi-permanent mold is a casting process -producing )luminum alloy castings - using re-

usale metal molds and sand cores to form internal

passages /ithin the casting. Molds are typically

arranged in t/o hal$es - the sand cores eing putinto place efore the t/o hal$es are placed

together. 0he molten metal flo/s into the mold

ca$ity and surrounds the sand core /hile filling the

mold ca$ity. #hen the casting is remo$ed from themold the sand core is remo$ed from the casting

lea$ing an internal passage in the casting.



0he re-usale metal molds are used time and

again& ut the sand cores ha$e to e replaced

each time the product is cast& hence the termsemi-permanent molding.

"emi-permanent molding affords a $ery high

precision ,uality to the casting at a reducedprice compared to the sand casting processes.



Aluminum composite alloy

• Material' 357SiC10p

aluminum composite alloy%

• Process'Semi/

permanentmold casting%

• Casting Supplier' Eck

,ndustries$,nc%$ Manito)oc$

isconsin%



The brake rotor as converted to an al!min!m metalmatri0 composite "((% alloy casting at a 5$ eight

red!ction, ith the same casting yield and itho!t aloss in performance.

n terms of mechanical properties, the al!min!m ((brake rotors mod!l!s and its ear rate in application

are the same as cast iron.



6ucket chain link for a con#eyor

system • Material'C75(0

nickel aluminum

bron9e%• Process'Permanent

mold casting%

• Casting Supplier'

Piad PrecisionCasting Corp%$+reensburg$Pennsyl#ania%



Pre$iously made from t/o steel stampings /elded

together /ith t/o tue sections and suse,uentlytin-plated for corrosion resistance 1r2& this rone

cast component 1l2 no/ is a one-piece permanent

mold casting.

0he cast component 1l2 exhiits good corrosion

resistance 1/ithout plating or



Manual !rip

• Material'Copperaluminum bron9e

alloy%• Process' Permanent

mold casting%

• CastingSupplier'

Piad PrecisionCasting Corp%$+reensburg$Pennsyl#annia%

6 k d f i l



6rake drum for commercial

high)ay Class 4 trucks and

trailers%

• Material'+ray iron%

• Process' Centrifugalcasting%



-elsted Di#ision-uronIs foot pedal

control le#er%

• /aterial> Zama! ,.

• :rocess> Diecasting.• %asting upplier>

%reco%ast" e&ille"

5hio.



Cast Component' Monoco"ue Scooter Chassis for ondaIs Super Sport Scooter%

Material'J,S ADC(1 :a 343 aluminum alloy e"ui#alent;%

Process' Diecasting%



,nstrument panel frame for the

Cadillac De.ille%

• /aterial> AZ91

magnesium alloy.

• :rocess> Diecasting.


)ntermet %orp’s

annibal :lant"annibal" /issouri.



• Cast Component' .al#e spacers for arren uppIs Sandpiper ,,

• air/actuated pumps%

• Material'KA/4 9inc alloy Process' Die casting%



.al#e spacers for arren uppIs Sandpiper

,, air/actuated pumps%

• /aterial> ZA-8 inc

alloy.

• :rocess> Diecasting.


%reco%ast" e&ille"

5hio.



Allen/6radley housing

• Process type

• Die casting

• Material used

• A,80 aluminum alloy

• Product and material

re"uirements and specialties

1. The component neee to be stury

enough to withstan the outsie

elements an pro&ie easy access

to the inner ri&e it encase.

*. :ortions o# the part are &isible a#ter

assembly" ma!ing cosmetics a

consieration.



*L 6AE CAS!,*+

The ;o-ake *andasting processconsists of sand molds

created !sing a ood,metal or plastic pattern.*and is mi0ed ith a!rethane binder anddeposited into a bo0

containing the pattern"and all necessaryformers and inserts% for

po!ring. illing a ood mold ith sand



PLD8C!S/ !E*S,L*E P8>>EN

(aterial) 8ray iron +rocess) ;obake sand

asting *!pplier) ?ellsville o!ndry, ?ellsville, hio



PEMA*E*! ML>D CAS!,*+

PLD8C!S • Material'C75(0

nickel aluminumbron9e%

• Process' Permanentmold casting%

• Casting Supplier'Piad PrecisionCasting Corp%$+reensburg$Pennsyl#ania%HCDT >A;



Suspension crossmember

• /aterial>,$

aluminum alloy.

• :rocess> :ermanent

mol casting.


%/)-:recision /ol")nc." ristol" )niana.



0his 4-l safety-critical component /as redesigned

to an aluminum casting from a steel /eldment&

resulting in a 67-l /eight reduction.

0he casting8s dimensional tolerances are held to 9.5

mm across the length of the part& a threefold

reduction o$er the pre$ious design.

0he casting8s mechanical properties include 77 !si

ultimate strength& 34 !si yield strength and 69.7 x

69 psi oung8s modulus.



6racket for a piston cooling system

• /aterial>9$,

aluminum brone.

• :rocess>:ermanentmol

casting.


Aurora /etals" 6.6.%.2iler )nustries3"

/ontgomery" )llinois.



Manual trip used in the electrical

industry • /aterial>%opper

aluminum brone

alloy.

• :rocess> :ermanent

mol casting.

• %asting upplier> :ia:recision %asting

%orp." 4reensburg"

:ennsyl&annia.

Three-bladed adapter for a



pcleaning br!sh on ind!strial

floor cleaning eB!ipment• .(aterial)/5-45-12 d!ctile iron.

• +rocess) 8reen sand casting.

• asting *!pplier) *mith o!ndry o.,(inneapolis.

• +revio!sly man!fact!red as a fo!r-pieceeldment, this component as redesignedas a single casting at a 73'casting,7#2,$$$'year savings to the c!stomer.

• The eldment e0perienced fail!re andbreakage !nder heavy shock loading. Theconversion to cast d!ctile iron eliminatedthe field fail!re and also incorporated thethree holes in each blade as-cast toeliminate post-process drilling.



• Cast Component' Carrier component

• Material'Steel Process' +reen sand Casting



Po)erhead for a pallet truck%

• /aterial> A,$-T

aluminum.

• :rocess>4reen san

moling.


?isconsin Aluminum7ounry %o." )nc."

/anitowoc" ?is.



Middle support for a bike rack on

public trains%

Material'535 aluminum% Process' Sand casting

!or"ue arm bracket for the after



!or"ue arm bracket for the after/

market automoti#e industry%

• Material'40/55/0 ductileiron%

• Process' Sand casting%



Center ring for a fall protection

system • /aterial> /anganese

brone.

• :rocess> 6ost #oamcasting.


)rish 7ounry an/anu#acturing" )nc."

eattle" ?ashington.

>if li h i t l lid f f t



>ifeline hori9ontal slide for safety

e"uipment%

• /aterial> /anganese

brone.

• :rocess> 6ost #oam

casting.


)rish 7ounry B/anu#acturing" )nc."

eattle.

cast products 2 (1)

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