64th Technical Conference & Equipment Exposition FINALISTS
Reactor Nozzle Assembly Reduces Cost with New Design T
his reactor nozzle assembly was previously machined from bar and made of three castings. “Our customer
approached TPM to help develop a better mass production solution for their nozzles,” stated Antonio Gracia, Vice President Sales and Marketing. “We worked with them to produce the casting as a two piece assembly and included branding to their parts. By using a casting to manufacture their parts, we drastically reduced the overall cost by eliminating welding and machining operations. Eliminating the welding of one of the pieces reduced the testing and weld inspection cost, as well as the overall cost and time for production. Using the investment casting process allowed for key features to be cast and as a result, only two features need minimal machining,” he concluded.
Similar parts on the market are machined from bar result-
ing in a higher cost to the end user. The part required a close fit with its mating part, as well as tight tolerances on all the dispersion slots on the side of the casting. The customer was able to attain new customers based on
this new design as the manufacturing cost of the end product was greatly reduced due to the casting process.
TPM, Inc.
PART: Reactor Nozzle Assembly Size: 8 lbs Alloy: CF8C Notes: Casting process eliminates costly welding and machining operations.
Five Piece Fabrication Conversion Saves Time and Money T
his component was formerly a fabrication of five pieces, machined from a billet/plate, and then bolted and
welded together. Now being cast as a one piece machined component, production cost for this part has reduced by over 30% and cut manufacturing lead times have been halved from the previous method of manufacture. The resulting configuration offers a smoother radii in the root and trailing edges than were obtained by the old method of manufacture. “The part is unique in size, mechanical property
requirements for the A357-T6 alloy (45ksi min tensile, 35ksi min yield, 3% min elongation) and the fact that it is supplied completely from the foundry including CNC machining, plating, painting and assembly,” Bruce Barron of Barron Industries explained.
PART: Forward Canard Section Size: 27 x 15” Alloy: A357-T6 Aluminum Notes: One piece investment casting convert saves time and reduced cost by 30%.
® Barron Industries October 2017 ❘ 23
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