CAST YOUR VOTE! ENTRY: CASTING 108
EVENT ATTENDEES VOTE FOR THE WINNERS CATEGORY: DEFENSE
This stator was produced using a shell and cores that were
produced via Additive Manufacturing. The entire ready to cast mold was printed simultaneously. This approach reduces the number of parts to build a mold, as it eliminates the need for platinum pins, quartz rods and chaplets used to support the cores and keep them from moving during the metal pour and the solidification. Core supports are printed with the core and shell. In doing so, product quality is greatly improved by eliminating variation in cast wall thickness, which directly contributes to improvements in cooling efficiency and engine performance.
(i.e. low risk lightweighting), which contributes to reduced fuel consumption (TSFC).
Reduced part weight is achieved through part integration Finished component cost (casting
and machining) is reduced by greater than 50%. This modular design approach can be easily tailored to long-life expendable, commercial, and defense applications.
Repeatable location of core to shell enables a uniform
metal flow during mold fill, reducing forces due to metal impinging on the shell. These forces are a known source of prime coat spallation that drives inclusions. Inclusions are one of the largest drivers of scrap and rework accumulating for up to 30% of scrap in the metals industry today. Additional savings are achieved by eliminating tool build
cost and manufacturing lead time. This approach bypasses wax injection, set up, inspection and dipping, eliminating sources
ENTRY: CASTING 109
of product variation. Manufacturing process risks are reduced from current practice as error proofing is now built into the part design. An added benefit is that the time to achieve a fixed casting process is greatly reduced. This has broad applications across all Commercial and DoD systems and can impact engines, airframes, ground vehicles and space, medical, oil & gas. Engine depot maintenance is simplified on out of production parts.
CATEGORY: FINE ART “The Veteran” was originally carved in 2005 in honor of the National
Year of the Veteran, from the trunk of a dying red oak that had stood for over a century. The statue is modelled on a decorated Veteran of World War II and survivor of Operation Overlord, the D-Day landing in Normandy, France. Due to its organic medium, the Veteran was originally carved from a sugar maple tree trunk, it became necessary to replace the original with an exact replica in 2016. In the fall of 2022, the Veteran was replaced again with another more durable replica, this time a bronze sculpture. Traditionally reproducing this sculpture, which would have required
the sculpture to be removed from the park, transported to the foundry for silicone rubber to be applied to the surface to make a rubber mold, was not an option. So Non-contact 3D scanning technology was employed to capture a digital model of the Veteran while it stood in the park. This took roughly 30-45 minutes. The wooden version of the Veteran was not removed from his base or the
park until a day or two before the installation of the final bronze sculpture. The bronze duplicate was such a good replication that some locals were unsure if the city had even replaced the sculpture yet, until after the unveiling.
® Name:
Dimensions: Integral 10 in. Diameter Alloy:
Cooled Integral Vaned Stator IN625
Name:
The Veteran
Dimensions: Approximately 10 ft. tall Alloy:
C87300 Everdur August 2023 ❘ 17
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