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Visit www.moderncasting.com for a slideshow of the simulation used for the Spartan casting.


offered uniform wall thicknesses throughout. “We reduced wall thicknesses to


Sigelock expects to sell about 10,000 Spartan hydrants in the first two years of production.


from the sand mold without damaging it). On the interior of the casting, the engineering team cored the hole where the ball screw would go to reduce porosity. Finally, mass was removed from the inside channels so those cores could be drawn naturally, as well. “Te cost of the tooling was much


less after the redesign,” Sigelakis said. “Much, much less.”


The new core design also eliminated a significant number of man-hours at the casting facility, contributing to the price reduction. To further curb costs, the design team was able to trim wall thick- nesses across the entire hydrant body. While the original design had many transitions between thick and thin sections, the final design


bring the mass down and achieve better castability for reduced scrap,” Applegate said. “Te redesign removed heavy sections that would have caused shrink, aided in solidification and reduced mass by 11%.” Te only thing left to set off the


hydrant revolution envisioned by Sigelakis is selling his product to municipalities—at home and abroad. “From day one when we told


Sigelock we could do this, they said we can go to the moon with this,” said Mark Koziorowski, sales manager for TyssenKrupp’s off highway group, who handles the Sigelock account. “And we are just about ready to light the fuse on this rocket.”


32 | MODERN CASTING October 2011


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