Case Studies Challenging Casting Redesigned With Coreless Features
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.
Shellcast, Inc.
PART: Valve Block Size: 8.5 x 7 x 5”h Alloy: 17-4ph
Traditional Manufacturing Collaboration With Additive Manufacturing Creates One-Of-A-Kind Wheel
“Once again, one of our favorite customers came to us
with a challenging detail that not only pushed our limits for size, but also took us into a new area in casting where we have never been before,” Paul Leonard of Aristo-Cast explained. “They first came to us with the design that their generative
design software came up with and we had to suggest a few minor changes to create a better investment casting and with those small tweaks, we then designed the gating configuration to be able to feed the part correctly and reduce the amount of machining that would be required to remove this gating,” Leonard concluded. The wheel was cast to size, the only machining that was required was to remove the gating system.
Aristo-Cast, Inc.
PART: Generative Design Wheels Size: 18” diameter, 7.05” deep Alloy: A357 Aluminum
January 2020 ❘ 33 ®
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