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Engine block of a 500 cc motorcycle

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Title: PowerPoint Presentation Author: N.RAMACHANDRAN Last modified by: RAMETTAN Created Date: 3/11/2004 11:11:58 AM Document presentation format – PowerPoint PPT presentation

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Title: Engine block of a 500 cc motorcycle


1
Engine block of a 500 cc motorcycle
  • Process typeDirect Shell Production Casting
    Material usedA356 T6 aluminumProduct and
    material requirements and specialtiesTypical
    requirements involved in high performance engine
    manufacture like high strength, strict tolerance
    etc...

2
Cellular phone keypad and display enclosures
3
  • Cellular phone keypad and display enclosures
  • Process type Thixotropic molding
  • Material used AZ-91D magnesium alloy
  • Product and material requirements and specialties
  • The components walls are between 0.8 and 1.0 mm
    thick, with a total casting weight of 105 grams.
  • Process requirements and specialties and
    specialties
  • Capability of accurately casting the small
    details involved and economical large scale
    production
  • Process Details
  • This component was cast by injecting semi-solid
    state magnesium into a closed die in a similar
    manner to plastic injection molding.
  • Problems Encountered. NA
  • Process advantages
  • Improved rigidity and impact resistance and
    impact resistance over previous plastic injection
    molding manufacture
  • Capability of providing electro-magnetic
    interference shielding without external coatings
    or plating.

4
(No Transcript)
5
  • Component 1.5 meter valve for a municipal water
    works
  • MaterialNo lead brass Process
    Green sand

6
  • Cast Component Steering column upper bearing
    assembly for Mitsubishi.
  • MaterialAluminum. Process
    Diecasting.

7
  • Air intake manifold for 4 cylinder engine

8
Ice cutter used in an industrial ice machine.
  • Process type Investment casting.
  • Material used 316 stainless steel.
  • Product and material requirements and specialties
  • High rigidity and hardness
  • Process requirements and specialties
  • No warping and stress concentrations to be
    developed.
  • Process Details
  • An investment precoat was applied to increase the
    surface smoothness of the pattern.
  • The expendable pattern was surrounded by a
    refractory slurry
  • Machining to specifications
  • Solution annealing

9
Infrared Microscope FrameProcess type
Vacuum moldingMaterial used A356-T6 aluminum
alloyProduct and material requirements and
specialtiesThe weight of the product is to be
minimum. The product should be sufficiently
rigid to avoid any errors. Process requirements
and specialties and specialtiesWall thickness
should not be greater than 0.2 in anywhere in the
casting. So draft should be minimum. Machining
of the various small parts that are present
should be minimum to reduce cost. Tolerance of
the order of 0.015-0.020 in. Process DetailsA
heater softens a thin plastic that drapes over a
pattern on a hollow carrier plate. A vacuum then
draws the film tightly around the pattern and a
flask is placed on the pattern to prepare it for
the back fill of sand. The sand is compacted,
the back of the mold is covered with a plastic
film and a vacuum is applied to the flask
Atmospheric pressure hardens the mold, preparing
it for the pouring of metal.
10
Pistol frame for Smith Wesson.
  • Process type Die-casting.
  • Material used A380 aluminum alloy.
  • Product and material requirements and specialties
  • Process requirements and specialties and
    specialties
  • First instance of manufacturing of the gun frame
    by die casting. Capability of economically
    producing large quantities.

11
Rocker arm for BMW engines
  • Process type Counter gravity investment casting
  • Material used Carbon steel.
  • Product and material requirements and specialties
  • As the camshaft rpm increases, the rocker
    arms run faster and hotter. These components must
    withstand the temperatures and pressure of engine
    operation.
  • Process requirements and specialties
  • Zero surface defects
  • Ability to handle extremely large
    production volume.
  • Process Details
  • Ceramic molds are manufactured from
    wax patterns
  • The molds are inverted and then
    filled with molten metal
  • (via pressure) from the bottom to
    the top.

12
V6 cylinder block for a 3.9 liter automobile
engine
  • Process type Cosworth precision sand casting.
  • Material used. 319 aluminum alloy.
  • Product and material requirements and specialties
  • Usual requirements of cylinder block like exact
    tolerance, rigidity etc.
  • Process Details
  • A cast-in cylinder liner process is used. Cores
    for the molding process are made of zircon sand
    (which has superior thermal characteristics) to
    minimize machine stock and required wall
    thickness.
  • Core oil galleries are as-cast, requiring no
    internal machining and minimal wall thickness.
    The Cosworth casting process utilizes a rollover
    casting technique that improves casting yield for
    the block to 72, reducing component cost for the
    customer.

13
Internal Interface Frame for LCD Digital
Projector
  • Process type Plaster mold with rapid prototyping
  • Material used Magnesium
  • Product and material requirements and specialties
  • Low weight High structural stiffness and low
    thermal expansion to maintain component alignment
    High thermal conductivity and high heat
    tolerance (Local temperatures as high as 250C.)
  • Process requirements and specialties and
    specialties
  • Ability to achieve complex thin wall shape and
    precision features with typical post-machine
    tolerances of /-0.1 mm. Near-net shape forming
    to minimize machining operations and cost.
    Capability of production rates up to 80,000 units
    per year
  • Process Details
  • An SLA resin model is made from the CAD file.
  • A silicon master mold is made from this resin
    model.
  • A reusable urethane model is made from the above
    mold.
  • Individual cope and drag molds are made.
  • Metal is poured into the mold and allowed to
    solidify
  • Sprue and riser is cut off(Due to near net
    casting no major machining operation is
    necessary)
  • Inspection and shipping
  • Process Advantages
  • Improved rigidity
  • Reduced component cost

14
Bull gear for rotating large platforms in the oil
industry
  • Process type
  • Material used
  • Product and material requirements and specialties
  • A high-strength alloy steel per ASTM-A-148, Grade
    115/95 with
  • minimum 115,000-psi ultimate tensile strength
  • 95,000-psi yield strength
  • 4 elongation
  • 30 reduction of area
  • diameter of 62 ft.
  • 558 teeth, 0.75 DP stub teeth.

15
GOLF CLUBS
  • Process type
  • Solid imaging
  • Material used. NA
  • Product and material requirements and specialties
  • Radical design over conventional golf clubs
  • Process requirements and specialties
  • Manufacture of two sets of irons from design in 1
    week
  • Continued..

16
  • GOLF CLUBS- Process Details
  • Actua 2100 from 3D Systems was chosen as the
    solid imaging device.
  • The printer transforms CAD ideaslike the golf
    clubsinto physical reality using solid imaging
    technology. . It uses an approach similar to ink
    jet printing, but the jets dispense a
    plastic-like material to create the solid model.
    It uses this plastic-like material to create wax
    patterns with very thin walls and intricate
    undercut geometry. In addition, the speed of the
    printer makes it possible to produce designs in
    one day, allowing timely product development,
    testing and creation. The printer also can
    generate wax prototypes that help to match the
    prototyping system to the production process.
  • 50 wax patterns were created on the printer and
    sent them to the investment foundry for casting
    and finishing. In investment casting, a ceramic
    shell is built around a wax pattern, which is
    burned out of the mold before molten metal is
    poured in.
  • Problems Encountered
  • Extremely small time frame gave no scope for
    process iterations and refinements.
  • Process advantages
  • The player who used the golf clubs produced won
    the tournament!!

17
ATM Counter
  • Process type Gravity permanent mold casting
  • Material used A360 aluminum
  • Product and material requirements and specialties
  • Tamper proof assembly Good aesthetic appearance
  • Process requirements and specialties
  • Production figures of up to 100 components/week,
  • The parting plane on the casting had to be
    horizontal
  • The metal feeding system into the mold could not
    use side feeders
  • Process Details
  • Redesign of the product from earlier
    manufacturing process (plastic injection)
    Modeling of the casting using a software named
    magma soft Pouring of the molten metal into
    the permanent mold The casting needed to be
    filled in less than 10 sec (to eliminate the
    possibility of pouring defects) with the aid of
    gravity only Solidification of the casting
    within 12-15 s.
  • Problems Encountered
  • Mold filling and solidification has to be quick
    to avoid the porosity. In a flat area of the
    casting, porosity could be only minimized and not
    completely avoided.
  • Process advantages
  • Reduced cost over previous manufacturing method
    (plastic molding) Improved surface appearance.
  • Improved functionality (tamper proof)

18
Heat exchanger used for a steam-generation
application.
  • MaterialClass 35 gray iron.Process Nobake sand
    molding.Casting Supplier Wellsville Foundry,
    Inc., Wellsville, Ohio.
  • The 115-lb, 23-in.-long casting contains seven
    rings of 31 fins each. The component originally
    consisted of seven fabrications welded together
    to form a continuous ring tube welded to an end
    cap and flange.
  • The new one-piece casting design (with 217
    0.25-in.-wide fins) features uniform wall
    thickness and is non-leaking because it has no
    weld joints.
  • The casting offers a significant lead time
    reduction compared to the previous
    fabrication/assembly, lasts longer and improves
    the efficiency of the final product while
    providing a significant cost savings to the
    customer.

19
Axle housing for Goodman Equipment Corp
  • .MaterialSteel.Process Chemically bonded
    sand.Casting Supplier Columbiana Foundry Co.,
    Columbiana, Ohio.
  • This 36 x 11 x 24-in. casting was originally
    designed as a machined weldment.
  • By converting the component to casting, a 33
    cost savings was realized by the customer due to
    the elimination of the assembly time for the
    component.

20
Investment Casting Reduces Sub-Assembly Time by
87, Cost by 51
  • The tab ring liner, originally designed as 16
    separate machined tabs that were welded together,
    was converted to a single investment casting,
    reducing sub-assembly cost by 44.00 and time by
    26 min. Pictured counter-clockwise from top are
    the ring welded onto the sheet metal tube, the
    cast double ring, the single ring and the
    completed assembly.

21
Manifold for fire-fighting equipment
  • Material65-45-12 ductile iron.
  • Process Green sand casting.
  • Casting Supplier Versa Iron and Machine, St.
    Paul, Minnesota.
  • This 90-lb manifold was converted from a
    stainless steel weldment at a per piece cost
    savings of 550.45 (annual savings of 220,180
    with 400 part volume).
  • The tooling payback for the pattern, coreboxes
    and machine fixtures was realized within the
    first 6 weeks of production

22
Chassis for joy stick tensioning in an aircraft
flight simulator for S.C.T., Inc
  • .MaterialA356-T6 aluminum alloy.
  • Process Nobake sand casting.
  • Casting Supplier Danko Arlington, Inc.,
    Baltimore, Maryland.
  • This 14-lb component was converted from an
    aluminum weldment at a cost (due to reduced
    welding and fabrication man-hours) and weight
    savings.
  • Measuring 16 x 9 x 14 in., the casting is a
    simpler design than the weldment with improved
    rigidity.

23
Fabrication (Left) Casting (Right)
  • Cast Component Annealing furnace pedestal for a
    steel mill.
  • MaterialASTM A-297 grade HH heat resistant
    stainless steel.
  • Process Nobake sand casting.
  • Casting Supplier Wellsville Foundry, Wellsville,
    Ohio.
  • This one-piece, 25-lb casting replaced a
    stainless steel fabrication at a 67 cost
    savings.
  • The cost reduction is due to the elimination of
    fabrication and assembly man-hours.

24
Air-ride suspension arm for buses that suspends
the bus frame on the front and rear axles
  • .Material80-55-06 ductile iron.
  • Process Green sand casting.
  • Casting Supplier Donsco, Inc., Mt. Joy,
    Pennsylvania.
  • Converted from a steel stamping/fabrication, the
    120-lb casting provided the customer a 50 total
    cost savings (including assembly time).
  • The foundry casts paints and machines the
    component, and assembles a sub-system for the
    customer. The assemblies are shipped directly to
    the customers manufacturing line

25
Bracket for a piston cooling system on a railroad
locomotive
  • .Material953 aluminum bronze.
  • Process Permanent mold casting.
  • Casting Supplier Aurora Metals, L.L.C. (Hiler
    Industries), Montgomery, Illinois.
  • This 0.8-lb component was converted to permanent
    mold casting to eliminate the leaks inherent in
    the previous manufacturing method. In addition,
    the conversion realized a cost savings by
    reducing man-hours and eliminating heat treatment
    as permanent mold casting achieves the required
    mechanical properties.
  • Permanent mold casting allows a stainless steel
    tube insert to be cast directly into the bracket.
  • The casting design and gating system were
    engineered using solidification modeling,
    ensuring a quality casting from the first shot.

26
Fuel rail housing for four-cylinder, 2.0- and
2.2-L passenger car models
  • .MaterialAluminum
  • .Process Semi-solid casting.
  • Casting Supplier Madison-Kipp Corp., Madison,
    Wisconsin.
  • An engine configuration required a fuel rail
    housing capable of withstanding high levels of
    impact without failure. The customer decided that
    traditional fabricated brazed steel tube and
    plastic designs would not meet the stringent
    impact requirements and opted for a cast
    component.
  • The customer, first-tier supplier and casting and
    machining component supplier worked together to
    develop a casting that met the 7000-lb crash test
    load while keeping costs to a minimum.
  • Increased dimensional accuracy of critical
    features produced close tolerance machining for
    special features and resulted in leak-free
    performance without impregnation (this was aided
    by semi-solids inherent low porosity
    characteristic).

27
Gearbox for Daytona Prototypes
  • Material356 aluminum
  • Process Nobake sandCasting Supplier Olson
    Aluminum Castings, Rockford, Illinois.
  • The 44-lb gearbox requires extensive machining
    after casting and therefore is produced void,
    porosity, oxide and shrink free.
  • 356 aluminum allowed the foundry to achieve the
    high strength-to-weight ratio necessary of
    components for competitive motor sports.
  • Sand casting and its low-cost tooling requirement
    allowed for engineering changes and quick tool
    modifications as well as eleven different
    components in the program to be produced in
    record time.

28
Tensioner pulley for tire manufacturing
  • MaterialGray iron
  • Process No bake sandCasting Supplier Wellsville
    Foundry, Wellsville, Ohio
  • This 175-lb component is used as a brake that
    puts tension on a 4 ft. wide roll of rubber
    feeding into a tire press.
  • Converted from a steel fabrication (two ring
    burn-outs with spokes), the foundry provided the
    end-user with a 50 cost savings.

29
Oil pump cover
  • MaterialDuctile iron
  • Process Green sandCasting
  • Supplier Cambridge Brass, Cambridge, Ontario,
    Canada.
  • This 70-lb component, which holds oil for a gear
    drive sump pump, was converted from a six-piece
    weldment at a 40 cost reduction.
  • The conversion to casting eliminated seven
    manufacturing steps for the end-user, reducing
    material handling. In addition, the elimination
    of weld joints eliminated oil leakage problems
    the fabrication was experiencing.

30
  • Prototyping for Direct Metal Casting Data to
    Castings in 12 hours

Pictured is a prototype sand mold and the
resultant aluminum pipe casting produced from
it.One of the hurdles facing todays foundries as
they try to grow market share is lead time.
Customers want sample cast parts today to fit
into their product designs for form, fit and
function. If the foundry cant deliver, then the
customer will turn to a fabricator for a quick
solution.
31
A bearing bracket used in the drive system on a
self-propelled lawn mower
  • .Material8620 steel alloy.Process Investment
    (lost wax) casting.Casting Supplier Signicast
    Corp., Hartford, Wisconsin.
  • This 0.91-lb bearing bracket casting, which was
    previously formed from the assembly of a
    laser-cut plate that was welded to a hub machined
    from bar stock, has the added ability to adjust
    the alignment and tension of the belts within the
    drive system.
  • The casting design provided an 83 cost
    reduction, which equals 12.65/component. Part of
    this cost savings is due to the simplified
    end-product assembly that results from the hex
    shapes being cast for adjustment purposes.
  • The finished cast component is supplied by the
    foundry after undergoing tapping, boring and
    plating.

Agricultural component
32
Knotter frame for a hay-baling machine for New
Holland
  • .MaterialASTM 842-85 grade 350 compacted
    graphite iron (CGI).Process Green sand
    casting.Casting Supplier R.H. Sheppard Co.,
    Inc., Hanover, Pennsylvania.
  • In the previous design, the end-user was
    experiencing failure (breakage) in the
    components thin sections during use. As a
    result, it was converted to a CGI casting to
    improve strength to 50,000 psi and durability of
    these sections.
  • The conversion to CGI and its improved strength
    also provided the foundry with an opportunity to
    reduce the weight of the component to 8.75 lb.

Agricultural component
33
Lawnmower gear and axle
  • .MaterialASTM 897 grade 200-155-01 austempered
    ductile iron.Process Green sand casting.Casting
    Supplier Applied Process, Inc., Livonia,
    Michigan.
  • Previously manufactured as a three-piece
    carburized steel assembly, the gear and axle
    casting was converted to austempered ductile iron
    at a cost savings.
  • After austempering at the heat treat facility,
    the casting is machined complete before shipment
    to the customer.

Agricultural component
34
Mower bracket.
  • MaterialDuctile iron.Process Green sand
    casting.Casting Supplier Dotson Co., Inc.,
    Mankato, Minnesota.
  • The customer experienced tolerance
    inconsistencies between fabricated parts on the
    original steel weldment, prompting the switch to
    a single component casting.
  • The original weldment cost the customer 12/piece
    to manufacture. By converting to ductile iron
    casting, the customer saves 60,000 annually.
  • In addition to casting, the foundry is machining
    the part, providing the customer with a finished
    appearance.

Agricultural component
35
Shifter fork assembly for a combine transmission
  • .Material953 aluminum bronze.Process Permanent
    mold casting.Casting Supplier Aurora Metals,
    LLC, Montgomery, Illinois.
  • This component previously was manufactured as a
    multi-part iron assembly. The pictured assembly
    consists of two components riveted together and
    pinned onto a finished shaft.
  • The stronger, redesigned cast component pictured
    is created from a stainless steel shaft that is
    pre-heated and locked in place in the permanent
    mold casting die as liquid aluminum bronze is
    poured around it.
  • The 1.5-lb finished cast component has a tensile
    strength of 65,000-75,000 psi and a yield
    strength of 25,000-27,000 psi. It also reduces
    necessary secondary operations and handling.

Agricultural component
36
CAD solid model (top), SLS polycarbonate pattern
(left), A356 aluminum casting (right).
CASTING PRODUCTS CONTINUED--
37
Cam clamp used to secure ambulance gurnees.
  • Material Stainless steel.
  • Process Investment casting.
  • Casting Supplier Independent Steel Castings
    Co., Inc., New Buffalo, Michigan.

38
Mounting bracket for medical centrifuge.
  • Material CF3M stainless steel.
  • Process Investment casting.
  • Casting Supplier Vestshell, Inc., Montreal,
    Quebec, Canada.
  •  

39
Duck bill for White Cap, L.L.C. to seal caps on
food jars.
   
  • Material316L stainless steel.
  • Process Investment casting.
  • Casting Supplier Northern Precision Casting
    Co., Lake Geneva, Wisconsin.

40
Fan frame hub for General Electrics CF-6-80C
engine for Boeings aircraft.
  • Process type Investment casting.
  • Material used Titanium.
  • Product and material requirements and specialties
  • Large dimensions(52-in.dia)
  • Process requirements and specialties
  • Capability of handling the problems encountered
    in large castings

41
Racing car upright
  • Material Titanium 6246.
  • Process Investment casting.
  • Casting Supplier Coastcast Corp., Rancho
    Dominguez, California.

42
Housing actuator for an engine for Hamilton
Sundstrand.
  • Material A203 aluminum alloy.
  • Process Investment casting.
  • Casting Supplier Cabiran, Ltd., Kibbutz Cabri,
    Israel.

43
AAW 5-M handheld missile-launching system
  • Process type
  • Investment casting
  • Material used A357-T6 aluminum
  • Product and material requirements and specialties
  • Maximum weight reduction to reduce operator
    fatigue
  • Process requirements and specialties
  • Reduction of wall thickness as much as
    possible(less than 0.04 in with the overall
    dimensions15 x 14 x 7.5 in)

44

The 5-lb casting is one-tenth
scale of the vacuum vessel for the National
Compact Stellarator Experiment (NCSX) being
developed by the Princeton Plasma Laboratory and
the Oak Ridge National Laboratory as the next
generation of fusion experiment. The scale model
was investment cast to determine the feasibility
of using a casting for a vacuum vessel with
complex geometry. To meet the rush timeline
(with the help of buycastings.com), SLS rapid
prototyping techniques were employed to make the
complicated wax patterns from a CAD/STL file in 2
weeks. Solidification modeling predicted the
potential hot spots and ways to optimize the
pour parameters. The foundry employed a
vacuum-assist casting method to cast the Inconel
625 air melt alloy with a consistent wall
thickness of 0.1 in. The entire vessel is
assembled by welding three equal segments cast by
the foundry.
  • Cast Component Vacuum Vessel for the power
    generation industry
  • MaterialInconel 625
  • Process Investment Casting
  • Supplier Bescast, Inc., Willoughby, Ohio

45
SEMI-PERMANENT MOLD CASTING Semi-permanent mold
is a casting process - producing Aluminum alloy
castings - using re-usable metal molds and sand
cores to form internal passages within the
casting. Molds are typically arranged in two
halves - the sand cores being put into place
before the two halves are placed together. The
molten metal flows into the mold cavity and
surrounds the sand core while filling the mold
cavity. When the casting is removed from the mold
the sand core is removed from the casting leaving
an internal passage in the casting.
46
The re-usable metal molds are used time and
again, but the sand cores have to be replaced
each time the product is cast, hence the term
semi-permanent molding. Semi-permanent molding
affords a very high precision quality to the
casting at a reduced price compared to the sand
casting processes.
PRODUCTS-------
47
Aluminum composite alloy
  • Material 359/SiC/20p aluminum composite alloy.
  • ProcessSemi-permanentmold casting.
  • Casting Supplier Eck Industries,Inc.,
    Manitowoc, Wisconsin.

48
The brake rotor was converted to an aluminum
metal matrix composite (MMC) alloy casting at a
50 weight reduction, with the same casting yield
and without a loss in performance. In terms of
mechanical properties, the aluminum MMC brake
rotors modulus and its wear rate in application
are the same as cast iron.
49
Bucket chain link for a conveyor system
  • MaterialC95410 nickel aluminum bronze.
  • ProcessPermanent mold casting.
  • Casting Supplier Piad Precision Casting Corp.,
    Greensburg, Pennsylvania.

50
Previously made from two steel stampings welded
together with two tube sections and subsequently
tin-plated for corrosion resistance (r), this
bronze cast component (l) now is a one-piece
permanent mold casting. The cast component (l)
exhibits good corrosion resistance (without
plating or
51
Manual Trip  
  • MaterialCopper aluminum bronze alloy.
  • Process Permanent mold casting.
  • CastingSupplier Piad Precision Casting Corp.,
    Greensburg, Pennsylvannia.

52
Brake drum for commercial highway Class 8 trucks
and trailers.
  • MaterialGray iron.
  • Process Centrifugal casting.

53
Felsted Division/Furons foot pedal control
lever.
  • Material Zamak 3.
  • Process Diecasting.
  • Casting Supplier CrecoCast, Seville, Ohio.

54
  • Cast Component Monocoque Scooter Chassis for
    Hondas Super Sport Scooter.
  • MaterialJIS ADC12 (a 383 aluminum alloy
    equivalent).
  • Process Diecasting.

55
Instrument panel frame for the Cadillac DeVille.
  • Material AZ91 magnesium alloy.
  • Process Diecasting.
  • Casting Supplier Intermet Corps Hannibal
    Plant, Hannibal, Missouri.

56
  • Cast Component Valve spacers for Warren Rupps
    Sandpiper II
  • air-actuated pumps.
  • MaterialZA-8 zinc alloy Process Die
    casting.

57
Valve spacers for Warren Rupps Sandpiper II
air-actuated pumps.
  • Material ZA-8 zinc alloy.
  • Process Diecasting.
  • Casting Supplier CrecoCast, Seville, Ohio.

58
Allen-Bradley housing
  • Process type
  • Die casting
  • Material used
  • A380 aluminum alloy
  • Product and material requirements and specialties
  • The component needed to be sturdy enough to
    withstand the outside elements and provide easy
    access to the inner drive it encased.
  • Portions of the part are visible after assembly,
    making cosmetics a consideration.

59
NO BAKE CASTING
The No-Bake Sand Casting process consists of sand
molds created using a wood, metal or plastic
pattern. Sand is mixed with a urethane binder and
deposited into a box containing the pattern (and
all necessary formers and inserts) for pouring.
Filling a wood mold with sand
60
PRODUCTS- TENSIONER PULLEY
Material Gray iron Process Nobake sand
Casting Supplier Wellsville Foundry,
Wellsville, Ohio
61
PERMANENT MOLD CASTINGPRODUCTS
  • MaterialC95410 nickel aluminum bronze.
  • Process Permanent mold casting.
  • Casting Supplier Piad Precision Casting Corp.,
    Greensburg, Pennsylvania.

BUCKET CHAIN
62
Suspension crossmember
  • MaterialB356 aluminum alloy.
  • Process Permanent mold casting.
  • Casting Supplier CMI-Precision Mold, Inc.,
    Bristol, Indiana.

63
This 26-lb safety-critical component was
redesigned to an aluminum casting from a steel
weldment, resulting in a 14-lb weight reduction.
The castings dimensional tolerances are held to
0.5 mm across the length of the part, a threefold
reduction over the previous design. The
castings mechanical properties include 44 ksi
ultimate strength, 32 ksi yield strength and 10.4
x 106 psi Youngs modulus.
64
Bracket for a piston cooling system
  • Material953 aluminum bronze.
  • ProcessPermanentmold casting.
  • Casting Supplier Aurora Metals, L.L.C. (Hiler
    Industries), Montgomery, Illinois.

65
Manual trip used in the electrical industry
  • MaterialCopper aluminum bronze alloy.
  • Process Permanent mold casting.
  • Casting Supplier Piad Precision Casting Corp.,
    Greensburg, Pennsylvannia.

66
Three-bladed adapter for a cleaning brush on
industrial floor cleaning equipment
  • .Material65-45-12 ductile iron.
  • Process Green sand casting.
  • Casting Supplier Smith Foundry Co., Minneapolis.
  • Previously manufactured as a four-piece weldment,
    this component was redesigned as a single casting
    at a 3/casting, 72,000/year savings to the
    customer.
  • The weldment experienced failure and breakage
    under heavy shock loading. The conversion to cast
    ductile iron eliminated the field failure and
    also incorporated the three holes in each blade
    as-cast to eliminate post-process drilling.

67
  • Cast Component Carrier component
  • MaterialSteel Process Green sand Casting

68
Powerhead for a pallet truck.
  • Material A356-T6 aluminum.
  • ProcessGreen sand molding.
  • Casting Supplier Wisconsin Aluminum Foundry
    Co., Inc., Manitowoc, Wis.

69
Middle support for a bike rack on public trains.
  • Material535 aluminum. Process Sand
    casting

70
Torque arm bracket for the after-market
automotive industry.
  • Material80-55-06 ductile iron.
  • Process Sand casting.

71
Center ring for a fall protection system
  • Material Manganese bronze.
  • Process Lost foam casting.
  • Casting Supplier Irish Foundry and
    Manufacturing, Inc., Seattle, Washington.

72
Lifeline horizontal slide for safety equipment.
  • Material Manganese bronze.
  • Process Lost foam casting.
  • Casting Supplier Irish Foundry Manufacturing,
    Inc., Seattle.
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