PCM’s plasma dynamo experiment
for its state university was one-of-a- kind in size and shape. But as a tool in the pursuit of scientific research, this casting also was unique in function.
Joining Two Hemispheres Funded by a $2.4 million grant
To cast each half of the dynamo, Portage Casting & Machining created a five-section mold that weighed nearly 75,000 lbs.
from the U.S. National Science Foun- dation in 2011, the Plasma Dynamo Experiment moved forward with plans to construct a 10-ft. hollow sphere that would be used to conduct experiments on plasma heated to 200,000 degrees Fahrenheit. Te dynamo spontane- ously creates magnetic fields, allowing astrophysicists to learn about similar phenomena in planets and stars. After a nationwide search for a
facility that could tackle a project of such scale, UW-Madison placed a pur- chase order with PCM, just 40 miles away. Te university initially explored welded fabrication, but PCM, whose foundry pattern division specializes in aluminum and offers on site machin- ing capabilities, convinced project manager John Wallace that it could deliver superior components. “We chose casting after realizing
Portage duplicated the molding and gating system from one pour to the next.
[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 engineers,
PCM received approval on a two-stage casting process that produced 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,
MEDIA RESOURCE Each hemisphere required 11,000 lbs. of aluminum poured into a 75,000-lb. mold. 40 | MODERN CASTING October 2013
Using the Actable App, scan this page to see a video of the dynamo’s installation at the UW-Madison. For instructions on how to use the app, go to page 3. To watch online, go to
www.metalcastingtv.com.
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