This page contains a Flash digital edition of a book.
The stainless steel propellers were required to prove dimensional accuracy with cloud scanning and laser scanning.


Casting Adjustments According to Fairbanks Morse, the pump maker empowered casting sup- pliers to use their expertise to manu- facture the parts cost-efficiently while meeting performance requirements. Te open relationship enabled Bay Cast to meet the firm deadline. With a start date of Oct. 5, 2009, the steel caster was charged with delivering its 11 propel- lers and housings by Jan. 10, 2011. It delivered them in November 2010. “Te project was intense and we


had to meet delivery dates, but the customer was open to ideas to address potential issues,” Holman said. Recent improvements to Bay Cast’s


facility enabled it to produce the pump parts. Te metalcaster installed two new 10,000-lb. (4,500-kg) induction furnaces in 2005, enabling it to pour the 10-ft. (3-m) diameter propeller, and it relined its internal car-bottom heat treating furnace to be able to bring the maximum temperature to 2,000F (1,093C). Tis allowed the steel caster to perform the required high temperature solution annealing in-house instead of outsourcing the work. Te project was


also Bay Cast’s first opportunity to use its upgraded modeling software, which allowed it to minimize casting issues on the first run and improve yield and cast- ing quality beyond the first article. St. Marys Foundry, St. Marys,


Ohio, made improvements of its own to handle the 57,0000-lb. (25,800-kg) ductile iron pump diffusers it makes for the West Closure Complex pump station. Each casting measures 12 ft. (3.6 m) in diameter and 9 ft. (2.7 m) in height—the largest ductile iron castings the facility has produced. “We make diffusers for other


customers, but nothing this large,” said Terry Lenhart, vice president of opera- tions. “We made some modifications to the facility to handle the load, such as increasing our crane capacity.”


Proof of Performance Te West Closure Complex pump


station is meant to handle the volume of water associated with a hundred- year flood (the highest waters a city can expect to see on average once every 100 years). Te volume of water is too much to test in the field, so pump components underwent strict quality analysis to prove they met specifications. For the propeller and housing parts produced at Bay Cast, the CNC-cut pattern equipment and first article castings were cloud scanned and overlaid on solid model data provided by Fairbanks Morse. “Tis allowed for a very quick and


visual representation of our dimen- sional results,” Holman said. “On subsequent castings, we used a laser


ONLINE RESOURCE


Visit www.moderncasting.com to watch a video about the construction of the West Closure Complex pumping station.


34 | MODERN CASTING March 2012 Bay Cast produced this 11,500-lb. pump housing in stainless steel.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82  |  Page 83  |  Page 84  |  Page 85  |  Page 86  |  Page 87  |  Page 88  |  Page 89  |  Page 90  |  Page 91  |  Page 92