designed for optimal castability, it still presented a challenge due to the tight tolerances specifi ed. “With thin walls like the ones used


in this casting, some distortion occurs through heat treatment and freeing the casting from the ceramic shell,” Willson said. O’Fallon performed compression strengthening on each aluminum part before heat treatment, using a press and a fi xture, to bring the walls back into tolerance. “It came out well. T e whole project was highly satisfactory.” As much of a pleasure as it was


for O’Fallon to cast, the customer enjoyed the benefi ts of avoiding hours of fabrication and assembly, achiev- ing higher precision than a fabrication and minimizing secondary machining. “I love taking this casting to diff erent events to show that if someone can visualize it, we can generally cast it,” Willson said. “How do you design a casting? Easy. Visualize the features you need and knit the material around what you want.”


May/Jun 2013 | METAL CASTING DESIGN & PURCHASING | 23


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