process was “the only process considered as an acceptable method to produce parts such as these.” “The design complexity of this casting is the result of melding of features such as pressure vessel, manifold- ing, and flanges for sealing and mechanical mounts,” he said. “Producing all of these features in a single cast piece eliminates costly fitting and welding of separate details, and the structural consequenc- es of added weld joints.” “Our designs are flight- or mission/system- These castings must


critical critical.


have tight controls on wall thicknesses because they are pressure vessels that have to hold up to high pressures at el-


evated temperatures. Varianc- es in wall thicknesses cannot be accepted,” he continued. “Since this is flight hardware, weight is also a critical re- quirement; which means we build smaller margins into the designs to save weight. Metallurgical


uniformity is


an absolute necessity, as evi- denced by the class and grade we specify, along with 100% radio graphic inspection.” Bruce Willson, sales


manager at O’Fallon Casting noted the finished 9.5” x 4.5” x 4.5” component is cast in A356-T6 Aluminum. “The subtle


the


internal


passageways,” complexity


of this design is really some- thing to behold, with all the external undercuts as well as


Willson said “The design flexibility of- fered by the investment cast- ing process allowed the op- portunity to sculpture a near net shape design with mini- mized material content, fit within the available envelope, and meet the seven prescribed interfaces of the aircraft,” he said. “In addition, a number of small features are incorpo- rated into the design, such as locating tabs and lightening pockets, which enhance the part functionality.” With the initial part con- cept, the customer elected to capitalize on another useful investment capability, to have accurate and metallurgically compliant castings produced as rapid prototypes.


rapid


“The investment cast prototypes improved


the customer’s speed-to-mar- ket, allowing them to more quickly


their customer for


deliver systems to testing,”


Willson continued. “Several subsequent iterations of rapid prototypes also allowed the customer the opportunity to further refine the design for subsequent production tool- ing.”


“The complex casting


was produced using soluble cores this casting represents well the extraordinary capa- bilities of the modern invest- ment casting process,” he add- ed. “The manifold requires only minimal secondary oper- ations, and despite the mix of thick and thin sections, meets Grade B metallurgy.”


Are You Taking Advantage of these Investment Casting Institute Member Benefits?


Investment Casters:  Monthly statistical program (North America only).


 Annual Sales and Profits Survey (North America only).  Annual Survey of Compensation Practices (North America only).  How’s Business Survey (North America only).  Free copies of INCAST Magazine to three designated employees.  Reduced prices for your company personnel to attend annual Technical Conference & Expo.


 Publications at half the price charged to nonmembers.  Members-only Spring Management Meeting (North America only).


 Members-only training courses and seminars.  Committee involvement.  Voting on motions proposed at membership meetings and through election of representatives to serve on the board of directors.


 Free listing in the Institute membership directory, which is distributed to buyers and users of investment castings.


 Reports of sales leads received by the Institute through its advertising efforts or participation in design shows.


 Discounts and other benefits with Yellow Transportation and Office Max. Suppliers:


 Discounts of 35% off nonmember rates on advertising in INCAST, the only monthly publication devoted to the investment casting industry.


 Discounts of approximately 33% off nonmember rates for exhibiting in annual Institute Expo


 A free listing in the Institute’s annual Buyer’s Guide.  A free listing in the Institute membership directory.  Free copies of INCAST Magazine to three designated employees.  Reduced prices for your company personnel to attend annual Technical Conference & Expo.


 Publications at half the price charged to nonmembers.  Members-only Spring Management Meeting (North America only).


 Members-only training courses and seminars.  Statistical summaries of investment casting bookings & sales trends (North America only).


 Opportunity to assist the industry through committee involvement.  Voting on special assessments with Regular members and for directors who are Affiliate members.


 Discounts and other benefits with Yellow Transportation and Office Max.


Phone 201-573-9770 Fax 201-573-9771 www.investmentcasting.orgQuestions?


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