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66th Technical Conference & Exposition


CASTING CONTEST


WINNERS Shellcast Wins Aerospace Award with Coreless Design


High pressure hydraulic systems can be prone to issues related to harmonic pulses within the oil and in-line attenuator chambers are often the solution to damp them out. Aircraft control systems are particularly challenging due to size and weight restrictions and Shellcast’s customer turned to investment casting to maximize performance. The traditional approach of pre-formed cores was dismissed


by Shellcast due to core delivery schedules and more importantly high heat retention within the core bodies. “The customer came to us when they had become schedule-critical with the Air Force. By using careful straight-dipping techniques, our process can achieve high reliability and dramatically reduce internal temperatures during solidification. This allows us to achieve tight NDT requirements in much less time. The customer has gone on record by saying that based on past experience, they were convinced this couldn’t be done but here we are today with a full approval and running production,” Gregg Nash, Quality/Engineering Mgr., Shellcast, Inc.


PART: Valve Block Size: 8.5 x 7 x 5”h Alloy: 17-4ph


Notes: Challenging casting redesigned with coreless features.


Cera-Met Takes Defense Casting Award with Yoke Casting


Used for an optical targeting system in a military application, the yoke casting houses all the optical components and is a key part of the systems rotational capabilities. Due to the complex design, internal passageways, thick to thin wall transitions and weight restrictions, investment casting was considered the best option for this configuration. Cera-Met worked closely with the customer on


modifications to improve the overall design for production as a casting. The part is currently produced from SLA patterns.


PART: Yoke Casting Size: 18 x 17 x 17” Alloy: A356-T6


Notes: Investment casting is best solution for casting with complex design, internal passages, weight and wall requirements.


® Cera-Met October 2019 ❘ 19 Shellcast, Inc.


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