Case Studies
Investment 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 Alloy: C355-T6
O’Fallon Casting
Investment Casting Surpasses Customer Expectations Of Cost And Lead Time
“When this company first came to us they were trying to design a casting using weldment knowledge,” comments Paul Leonard. “After several iterations and our input, we finally agreed on a design that would achieve everything that they initially wanted and much more, without any of the machining that would be required for a weldment.” The most difficult challenge of this combustion heat
exchanger was its 66 slots. It took the foundry several iterations before finally achieving 100% fill of the 0.034” thick ribs, while keeping the slots clean and achieving the +/- 0.001” tolerance requested by the customer.
By manufacturing this component as an investment
casting rather than as a weldment, the customer realized a shorter production lead time and lower manufacturing costs than originally anticipated.
PART: Combustion Heat Exchanger Size: 10.100 x 3.125 x 3.560” Alloy: Inconel 625
Aristo-Cast, Inc. 28 ❘ August 2020 ®
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