Breaking Down Barriers ”We take a good deal of pride in the prototyping, and
we also are one of only two that I know of in the U.S. and from what I’m told only seven in the world that are invest- ment casting magnesium,” said Ziemba. “T rough research and development here, we’ve managed to overcome the issues with metal mold reaction when it comes down to casting magnesium.” Aristo Cast has not patented its magnesium investment
casting process. But, it is in the process of drawing up a licensing agreement with a magnesium company in Israel. Although magnesium has a reputation for burning, the Elektron 21 magnesium alloy used in aircrafts has very low fl ammability, according to Ziemba. “It has just been approved for seat brackets in the Airbus,” he said. “And when it comes to aircraft, on say a 737, for every 500 lbs. of weight they can take out of that plane, they save a quarter million dollars’ worth of fuel. Magnesium casting vs. aluminum is going to be more expensive, but the payback is very good.” T e fi rm also recently formed a partnership with
Materion, Elmore, Ohio, to produce shells for its AlBeCast alloy, which has a high cost. “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 lightweight parts for a prototype handheld military system. One of the cast- ings produced in that project over the past year received the “Best in Class” award in the 2014 Metal Casting Design & Purchasing Casting of the Year competition.
“We are using cast magnesium alloy to help reduce weight, and the investment
绩，而据我所知我们是美国仅有的两个镁合金熔模铸造 企业之一，据说，也是全世界仅有的7个镁合金熔模铸 造企业之一，”Ziemba说。 “通过研发，我们已经成 功克服了生产中镁合金与金属模具反应的问题。” Aristo Cast公司还没有申请镁合金熔模铸造工艺 的专利。但是，公司正在与一家以色列镁合金公司制 定授权协议。“虽然镁有易于燃烧的特性，但是，用 于飞机制造的Elektron21镁合金具有非常低的可燃 性。”Ziemba说，“这种材料刚被空客公司批准用于 座椅支架，例如737飞机，每减轻500磅（约227kg） 的重量，就可节省25万美元的油耗。与铝合金相比，镁 合金铸件更昂贵，但回报率非常高。” 最近，公司与俄亥俄州埃尔莫尔的Materion公司建立 了合作关系，为其提供高成本的铝铍合金壳体（见第10 页）。Ziemba说：“我们内部生产所使用的阻燃镁合金 同样在他们的合金生产中表现良好，我们是团队合作的 关系。”
美国埃尔比特系统公司（新罕布什尔州梅里马克）机 械工程师Bill Schmidt，与Eric Ziemba（Eric Jacob的 儿子）合作开发手持式军用部件原型的轻量化零件。去 年，该项目中的一个铸件获得了“2014年铸件设计与采 购”年度铸件评比的“最佳铸件”奖。
“我们使用镁合金以减轻铸件重量，而熔模铸造工
This electronics housing Aristo Cast
produced for Elbit Systems of America involved casting not only the magnesium part but the cavity for the wax injection necessary to produce it.
这是Aristo Cast公 司为美国Elbit系统公司 生产的电器壳体，不仅采用镁合 金而且用注蜡的方式生产壳体空腔。
December 2014
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