63rd Technical Conference & Exposition
CASTING CONTEST
T WINNERS Stator Housing Takes Aerospace Honors
he unique aspect of this casting is that it includes extensive external mounting features that act as attachment and support points for all the components of an electronic system and dual motor controller. The base casting of aluminum A357 includes precision aerodynamic stator vanes, a motor case with ventilation holes and a cast in steel bearing liner. The casting also includes an integrated fan impeller containment ring and mounting brackets that support the installation into the aircraft.
PART: Stator Housing Size: 9” diameter x 13” h Alloy: Aluminum A357 Notes: This is a conversion from a 2 piece hog- out with a pressed in steel insert. Benefits include approximately 17-20% reduction in cost from previous designs.
Carley Foundry, Inc. Diving Helmet Takes Top Commercial Casting Award S Shellcast, Inc.
PART: Diving Helmet Size: 12 x 14 x 14” Alloy: 316 Stainless Alloy Notes: Final design represents a 20% weight reduction for customer.
14 ❘ October 2016 ®
hellcast, Inc. was contacted by a customer who indicated that they needed a high integrity component that they found just couldn’t be made using fabrication and/or a sand casting approach. Originally a bronze sand casting, the helmet was plagued with recurring issues of porosity and inclusions. After a long and largely unsuccessful development effort, investment casting was chosen to allow design
freedom and incorporate critical breathing and
communications connectors as an integral part of the design. “We can’t have leaks!” and “How thin can we make
this?” was often heard while the design evolved. High strength material and a lower weight part was proven by prototype casting using a SLA model before committing to production tooling.
Design confirmation was made possible by SLA modeling and casting prototyping before committing to hard tooling. Complexity of the shape increased during this phase, allowing the customer to eliminate additional sub-components and their seals. Development time was stretched out by geography and
travel difficulties. “Without CAD files, Google Translator, and Skype we would have never pulled this off,” stated Bob Johnson, President of Shellcast, Inc.
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