15th World Conference on Investment Casting FINALISTS
Rudra Castings Pvt. Ltd. Named as Casting Contest Finalist for Defense Application
This “Shell Part” is a complex component which features
intricate internal passages, measures 68 mm x 38 mm (2.658 in. x 1.496 in.) and is manufactured from 40Ni6Cr4Mo3 alloy. The challenge posed by this component was producing it cost effectively. To do so, it became necessary to produce the casting without ceramic cores, which became the largest technical hurdle faced by Rudra Casting engineers. The company solved this matter by creating a brass
“punch” or insert for use in the wax die. After injection, the punch was removed in sections, leaving virtually no parting line.
The internal cavity could then be formed during the dipping process and cast conventionally.
PART: Shell Part Size: 68 mm x 38 mm Alloy: 40Ni6Cr4Mo3
By adopting this
approach, component manufacturing costs were reduced by nearly 50%.
Rudra Castings Pvt. Ltd.
Atlantic C&E Named as Aerospace Finalist for Casting Conversion
This air compressor wheel was formerly produced as a
two-piece CNC machining which was assembled through dip brazing. This part is unique in both its small size (2.12 in. in diameter and 1.59 in. in height) and its required alloy, A205 Aluminum.
The small scale geometry creates an extremely
tiny compressor exit opening of just 0.04” and its eight main blades and eight splitter blades can be as thin as 0.026 in.. Given the small geometry and tight internal passages, this part could not be made with traditional wax tooling. That combined with a maximum surface finish requirement of 125 RMS necessitated that it be ordered as a 3D printed wax pattern and cast using the Solid Mold process. The high-performance requirements of this compressor
wheel dictated the use of the high-strength A205 alloy. These parts must meet the strict requirements laid out in the AMS 4471 material specification including florescent penetrant and x-ray inspections before being approved to ship. The customer benefited from purchasing this part as a casting as it reduced manufacturing complexity while improving operational performance. The cast component’s
®
PART: Compressor Wheel Size: 2.12 dia. x 1.59” high Alloy: A 205
mechanical properties exceed that of the hog out allowing the part to be spun at higher RPMs for increased performance.
August 2022 ❘ 19
Atlantic C&E
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