68th Annual Technical Conference & Exposition
CASTING CONTEST
WINNERS
O’Fallon Casting Produces One Piece Aerospace Pump Housing
This Pump Housing casting was made in investment from the start, resulting from proven customer savings from prior casting conversions of similar components. Weight is a key factor when manufacturing any component that flies. This casting affords the customer proper fluid distribution at a significant weight savings over a fabrication. Additionally, products produced by fabrication have a higher propensity for assembly defects. Manufacturing the component as a one-piece casting eliminated such defects. This component, produced from C355-T6 alloy, measures
13 in, x 7 in. x 7 in., which is a smaller configuration than what would result from a fabrication.
It features multiple
interconnected core passages of varying depths and diameters throughout the casting. The casting is comprised of a combination of thin walls in certain areas and large masses of metal in others. Along with the intricate core passage areas, the casting has a very tight profile tolerance, and strict metallurgy and high-pressure tightness requirements, making this component ideally suited for the investment casting process.
O’Fallon Casting
PART: Pump Housing Casting Size: 13 x 7 x 7“ Alloy: C355-T6
Barron Industries Converts Military Weldment To Investment Casting Using the investment casting process, Barron Industries
converted a distorted multi-piece welded fabrication into a one-piece lightweight and more durable HVAC component. Made of A356-T6 Aluminum, the thin-wall HVAC Diffuser is used in a military vehicle with tight packaging constraints. Barron performed the required digital radiography and
fluorescent penetrant testing in-house and achieved tight dimensional tolerances by performing a secondary “coining” operation. Using the latest additive manufacturing techniques, Barron produced an SLA Quickcast RP pattern to prove the concept and manufacturing method. In order to meet test vehicle requirements, the diffuser was designed, cast, machined and painted in just eight weeks
PART: Air Diffuser Size: 7.5 diameter, 4” tall Alloy: A356-T6
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Barron Industries October 2021 ❘ 29
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