PCM delivered the two cast hemispheres in November 2011, though it continues to receive orders for dynamo accessories.
comprised the centerpiece of Bay Cast’s $1.3-million contract with the NSCL, the orders haven’t stopped. “We’ve got other, smaller projects
that are ongoing,” Holman said, “but not to the scale of this project.”
Joining Two Hemispheres Funded by a $2.4 million grant
from the U.S. National Science Foun- dation in 2011, the Plasma Dynamo Experiment at the University of Wis- consin, Madison, Wis., moved forward with plans to construct a 10-ft. hollow sphere that would be used to conduct experiments on super-heated plasma. Te dynamo spontaneously creates magnetic fields, allowing astrophysi- cists to learn about similar phenomena in planets and stars. Much like MSU’s search that ended
in its own backyard, UW-Madison ended up placing a purchase order with Portage Casting & Mold Inc. (PCM), just 40 miles away. Te university ini- tially explored welded fabrication, but PCM, whose foundry pattern division specializes in aluminum and offers on site machining capabilities, convinced project manager John Wallace that it could deliver superior components. “We chose casting after realizing
[our] requirements could be met and recognizing advantages of casting such as cost, shape, flexibility, no welds and cast-in cooling lines,” said Wallace, an engineer in the university’s plasma physics department. “To us, it was like having a very large 3-D printer.” Working with university engi-
neers, PCM received approval on a two-stage casting process that pro- duced the sphere in separate, nearly identical halves. “Two castings were required to
complete the hemisphere assembly,” said Dennis Griep, PCM president. “Each casting was processed separately approximately 45 days apart in mild, dry conditions, and PCM duplicated the molding and gating process to achieve consistent casting geometry.” Considering the complexity of the
large-scale project, university profes- sors and PCM engineers benefitted from the local connection. “It was an enormous advantage to actually talk to the people making the
Sept/Oct 2013 | METAL CASTING DESIGN & PURCHASING | 33
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