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66th Technical Conference & Exposition


CASTING CONTEST


FINALISTS


O’Fallon Casting Reduces Weight and Assembly Cost of Critical Aircraft Component


This aircraft engine pump housing is an excellent example of how the investment casting process can reduce manufacturing time and cost while providing the customer with a more robust product than its fabricated counterpart, thus enhancing operational life. In utilizing the investment casting process, O’Fallon


Casting was able to decrease the overall size and number of pieces in the pump assembly. Instead of multiple pieces with less complex geometries being assembled together, this one piece investment casting saves them weight and eliminates future failure points at the assembly location. With multiple internal passages, with varying diameters, depths and tight tolerances, combined with grade B metallurgical requirements, components of this type pose challenges that are most suitably addressed to the investment casting process.


PART: Pump Housing Size: 10 x 9 x 5” Alloy: C355-T6


Notes: Investment casting reduces weight and assembly cost of critical aircraft component.


Conversion from Vacuum Melt to Air Melt Reduces Cost


An aerospace customer purchased an aluminum casting for a light helicopter electronic part assembly which was vacuum melted. To reduce the weight of the assembly, a new design included a wall thickness only 1.50mm. As this part is used for the assembly of printed circuit boards, heat removal is very important. For effective heat removal, the design features 280 fins on the inside walls of the casting. Because of the thinner walls, large number of heat sink fins, critical application, stringent non-destructive testing & acceptance and size of the component casting manufacturing, by air melting is extremely difficult. Turbo Cast (India) Pvt. Ltd. provided solution for the customer by changing manufacturing process from vacuum melt to air melt and reduced the cost of manufacturing by more than 50%.


PART: Box Casting Size: 310 x 200 x 130 mm Alloy: AS7G03


Notes: Conversion from vacuum melt to air melt reduces cost.


®


Turbo Cast (India) Pvt. Ltd. October 2019 ❘ 23


O’Fallon Casting


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