Each 100-ton disk was assembled from nine castings that were machined in house thanks to Bay Cast’s recent expansions.
one-of-a-kind in size and shape. But as tools in the pursuit of scientifi c research, these castings also were unique in function.
Casting a Jigsaw Puzzle Bay Cast Inc. specializes in heavy-
sectioned fi nished steel castings, while its sister company, Bay Cast Technologies, handles large-format precision machining services. When the National Superconducting Cyclo- tron Laboratory (NSCL) at Michigan State Univ. (MSU), East Lansing, Mich., began searching for bids for its 200-ton cyclotron stopper and its castings, the fi rm was an ideal candi- date, even without the added benefi t of being an hour and a half away. When completed, the cyclotron
will act as a gigantic magnet with a gas-fi lled chamber that will create thermalized ions by slowing beams of short-lived isotopes. By doing so, scientists can study rare isotopes and low-energy nuclear reactions. Owned by brothers Max, Jason and
Scott Holman, the Bay Cast com- panies handle short-run jobs in mild
and alloyed steel castings up to 70,000 lbs., and stainless steel castings up to 30,000 lbs. With plenty of capacity to handle such a project, the Holman brothers also had a family connection to the university and its endeavors in particle physics. In the 1970s, Scott Holman Sr.,
who would go on to establish Bay Cast before selling the business to his sons, was general manager of Bay City Foundry, which provided equip- ment for MSU’s original cyclotron. Four decades later, MSU and the next
“
generation of Holmans had another contract in hand. “We had a history with them,”
said Jason Holman, vice president and quality assurance manager, Bay Cast. “We had the ability to cast it and machine it, and we were nearby. It was interesting how everything came together.” T e NSCL project features 18
castings that will be assembled to form two massive disks. Four crescent-shaped components, each weighing nearly 55,000 lbs., will
We chose casting after realizing our requirements could be met and recognizing advantage. such as cost, shape, fl exibility, no welds and cast-in cooling lines. To us, it was like having a very alrge 3-D printer.”—JOHN WALLACE
Sept/Oct 2013 | METAL CASTING DESIGN & PURCHASING | 31
Cyclotron photos courtesy Michigan State University
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