simplifying the component from 34 pieces of steel that required sawing, rolling, machining, fit-up and welding to a single casting. Such a savings is significant, but the benefits extended beyond the bottom line. “It’s not just about saving money,


it’s also about freeing up time to do more value-added things, like add- ing assembly capacity and selling the product,” Dulaney said. Te casting also performed above


expectation when the customer’s engi- neers put the component through an intense series of tests. “It’s supposed to last forever and


Pier Foundry’s engineering team ran multiple simulations for the hub, which included 10 isolated sections extending from the central hub.


that’s what our customers expect,” said the customer’s engineer. “I did a lot of destructive testing when we received the castings. We built the hub into an impeller and fired steel rods at it. We couldn’t break the thing. We haven’t had them in the field for 10 years yet, but from our testing we believe they are plenty capable.”


42 | MODERN CASTING February 2015


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