casting vs. aluminum is going to be more expensive, but the payback is very good.” Te firm also recently formed a part- nership with Materion, Elmore, Ohio, to produce shells for its AlBeCast alloy, which has a high cost (see p. 10). “Our magnesium inhibiting that
we use for our internal product works very well for their alloy, as well,” said Ziemba. “So, we’re teaming up.” Bill Schmidt, mechanical engineer,
Elbit Systems of America, Merrimack, N.H., has been working with Eric Ziemba (Jack’s son) on developing light- weight parts for a prototype handheld military system. One of the castings pro- duced in that project over the past year received the “Best in Class” award in the 2014 Metal Casting Design & Purchas- ing Casting of the Year competition. “We are using cast magnesium alloy
to help reduce weight, and the invest- ment casting process allowed us the most geometric freedom and the abil- ity to keep the walls thin in noncritical areas. Aristo Cast provided in-depth support and design for manufacturing, and they kept us up to date during the fabrication of our parts with progress reports and pictures along the way,” said Schmidt. “Te team here was impressed with the fit and finish of all of the parts and the end customer was impressed with the light weight of the prototype product.”
The shop will add a new piece of equipment this year to aid the operators in dipping large castings.
Anticipating Needs Another key to Aristo Cast’s success
lies in providing model customer service. “We track orders so closely that we
know a customer is going to reorder something before they do, and we’ll start running it,” said Walla. “Every- body’s so tight in today’s economy, they want to be able to place the order and have it next week, so we keep ahead of the game.” Te company recycles its scrap,
and every sprue poured is fitted with
a coupon that is removed and sent to spectrometry for quality assurance. “For every alloy and for every
part, [production requirements] vary,” Walla added. “Te number of coats of ceramic depends on the alloy, for example.” Te ceramic shell removal process varies, as well, and the opera- tors are skilled at making those deter- minations to ensure part quality. “We talk about each job at the beginning and the end, to discuss what works and what could be done to improve the process next time,” she said. With knowledgeable staff, a solid
base in investment casting, a growing prototyping business and magnesium use projected to increase, Aristo Cast holds great promise for the future. Its customers know they can depend on its performance and willingness to take on the tough jobs. “Henry Ford said, ‘Whether you
Aristo-Cast provides completed castings with in-house operations from design through finishing.
think you can or you think you can’t, you’re right.’ So, if you go into a project with the attitude that it’s too difficult or it won’t succeed, then you won’t succeed. Never let it get that way with you,” said Ziemba. “I’ve set my goals and pretty much hit them all, but it’s more fun chasing the goal than it is once you achieve it, because it’s an end. And I don’t want anything to end. I’m having too much fun.”
June 2014 MODERN CASTING | 21
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