tracker to qualify and quantify the machining and blade accuracy on the pumps and housings.” T e inlet castings produced by
Decatur Foundry were required to pass 100% physical and chemical certifi ca- tion with ultrasonic verifi cation in criti- cal sections of the 140-in. cylindrical casting, which featured 6-ft. diameter openings on both ends. According to Lenhart, St. Marys’
diff user castings had to pass hydro testing for leaks to prove it would be up to the challenge of 800,000 gallons of water per minute. To promote the water fl ow, the interior walls of the part also had to achieve a C40 surface standard, which he described as a little rougher than the texture of a worn emery board. “We designed the tooling and
coreboxes in such a way to help ensure a smooth fi nish on the fl ow surfaces,” Lenhart said. Each casting features seven vanes, which are 4-in. thick, tapering to 1 in.
Each diffuser casting features seven fi ns that taper from 4 in. to 1 in. The casting required 24 cores.
March 2012 MODERN CASTING | 35
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