INTERN Spotlight
“Jacob showed an eagerness to learn all he could about the investment casting process and enthusiastically tackled many projects... Jacob displayed many leadership characteristics during his time at O’Fallon Casting. His positive attitude and ability to think outside of the box allowed him to have a positive impact on the company. He showed the ability to work well with individuals of all levels of the organization. Jacob understood the expectations for him and thus was able to complete his tasks without constant supervision.”
– Matt Cavins, O’Fallon Casting
JACOB HUXOL O’Fallon Casting
Through
it is one of the most dynamic studies. During my internship
W at O’Fallon
Casting, I researched slurry viscosity measurement, thermal analysis of a drying shell, and shell permeability along with how all impact casting quality. I had a positive learning experience and I hope to pursue many future endeavors in investment casting.
Watching slurry dry is no quick and easy feat. It requires patience, persistence, and a handy infrared gun to start. For my drying study, I attached a temperature/humidity sensor to the walls of sample parts. Study one resulted in blurry images with consistent temperature readings; studies two and three featured clearer thermal images but failed to record temperature. Studies four and five recorded ambient room temperature with sharper thermal images and internal temperatures and humidity. My patience and tenacity produced essential data that will improve conveyor line efficiency with faster drying times and dryness indicators.
atching slurry dry may sound like the most tedious task in investment casting, but
trial and error, I
implemented methods to measure shell permeability reusing PVC pipes. I designed an aluminum adapter that attached to the hangers on the conveyor line. Once the shell is built around the pipe, dry ice is compressed inside the tube and the PVC contracts for the shell to slide off. With this study, I found autoclaved shells are less permeable than shells only burned out. Prototypes, which are not autoclaved, typically yield better castings than common wax parts. I also found six-layer parts are more permeable than eight-layer parts and yield less nonfill and gas porosity for A357 castings.
I explored the relationship between human error and experimental results using stopwatches and Zahn cups. In this process, a robotic arm emits a frequency and consistently measures the slurry viscosities. I recorded Zahn measurements of the precoat slurry and compared results to arm values. Over time, I made more accurate estimations and implemented values for an automatic measuring system. As a result of my work, the precoat slurry will require less maintenance and will have a readout for continuous feedback.
stemmed from lack
Most major challenges I overcame of
experience.
During the first few weeks of my internship, I possessed no knowledge of conducting quality assurance tests and simulations in Procast. However, after a few months and innumerable questions, I succeeded. I also discovered functionality trumps aesthetics; duct tape may look ugly but works well on the conveyor line after the sensor housing breaks. I was astounded by the variety and complexity of the results. Given the positivity of my experience, I would like to focus on investment casting as a metallurgical engineer. More distantly, I would like to explore manufacturing components in space. Yesterday, I studied slurry to improve industry standards for today. Tomorrow, I dream to improve methods that will propel industry to the stars. I am thankful for the learning opportunity given to me and I look forward to further pursuing investment casting.
December 2019 ❘ 31 ®
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