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Virtual Technical Conference & 3D Exposition


CASTING CONTEST


WINNERS


O’Fallon Casting Consolidates Multi-Piece Assembly into Single Piece Casting; Wins Aerospace Award


Working with the customer, O’Fallon Casting consolidated a multi-piece fabrication into a single investment cast component, affording the customer the opportunity to reduce the overall size of the pump housing as well as the costs associated with assembly and multi-component sourcing. This pump housing casting contains multiple interconnected core passages throughout the inside of the casting, with varying diameters and depths. The combination of thin walls in certain areas, large masses of metal in others, a very tight profile tolerance, grade B metallurgical requirements and high pressure tightness requirements make this component a challenge that is ideally suited for the investment casting process.


PART: Pump Housing Size: 11 x 8 x 7 in. Alloy: C355-T6


Notes: Casting conversion from fabrication/assembly O’Fallon Casting Students Collaborate on Investment Cast Bowie Knife


Traditionally a forged product, the Bowie Knife project not only demonstrates the breadth of the techniques being taught at Pittsburg State University, but it also offers students valuable lessons in project management and industry collaboration.


The success of this project demonstrates capabilities in casting simulation, mold/die design, CNC machining, wax injection, investment casting, heat treatment, additive manufacturing, finishing, and craftsmanship. This knife was completely 3D modeled by the team. During the design phase, a few prototypes were additively manufactured created and then the students conducted casting simulations to produce gate design.


Considering all proper contraction rates, a die was 3D modeled. A Mastercam program was written to CNC machine the die, which was put to work on the University’s wax injection press. Students collaborated with ICI Member companies Signicast and the American Foundry Group to shell and cast the knives in CA6NM Stainless steel. After cut off, the knives underwent secondary machining operations and heat treatment. The knives were then hand worked to attach a walnut handle, secured with three brass pins. The aluminum bronze pommel was then attached, and the knife was hand polished.


®


Pittsburg State University


PART: Bowie Knife Size: 22 x 5” in.


Alloy: CA6NM Martensitic Stainless Steel Notes: Casting Conversion


October 2020 ❘ 27


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