Cast Products 2
Cast Products 2
Cast Products 2
Process type
Direct Shell Production Casting
Material used
A356 T6 aluminum
Product and material requirements and specialties
Typical requirements involved in high performance engine
manufacture like high strength, strict tolerance etc...
Air intake
manifold for
4 cylinder
engine
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Ability to achieve complex thin wall shape and precision features with typical post-machine tolerances of +/-0.1 mm. ; Near-net shape forming to minimize machining operations and cost. ; Capability of production rates up to 80,000 units per year
Process Details
An SLA resin model is made from the CAD file.
A silicon master mold is made from this resin model.
A reusable urethane model is made from the above mold.
Individual cope and drag molds are made.
Metal is poured into the mold and allowed to solidify
Sprue and riser is cut off(Due to near net casting no major machining operation is necessary)
Inspection and shipping
Process Advantages
Improved rigidity
Reduced component cost
Process type
Material used
Product
and
material
requirements and specialties
A high-strength alloy steel per
ASTM-A-148, Grade 115/95 with
minimum 115,000-psi ultimate
tensile strength
95,000-psi yield strength
4% elongation
30% reduction of area
diameter of 62 ft.
558 teeth, 0.75 DP stub teeth.
GOLF CLUBS
Process type
Solid imaging
Material used. NA
Product and material
requirements and specialties
Radical design over
conventional golf clubs
Process requirements and
specialties
Manufacture of two sets of irons
from design in 1 week
Continued..
ATM
Counter
1.
Chemically bonded
sand.Casting Supplier:
Columbiana Foundry Co.,
Columbiana, Ohio.
This 36 x 11 x 24-in. casting
was originally designed as a
machined weldment.
By converting the
component to casting, a 33%
cost savings was realized by
the customer due to the
elimination of the assembly
time for the component.
.Material:Aluminum
Pictured is a prototype sand mold and the resultant aluminum pipe casting
produced from it.One of the hurdles facing todays foundries as they try to
grow market share is lead time. Customers want sample cast parts today to fit
into their product designs for form, fit and function. If the foundry cant deliver,
then the customer will turn to a fabricator for a quick solution.
Agricultural component
Agricultural component
Agricultural component
Mower bracket.
Agricultural component
Agricultural component
medical
Fan frame hub for General Electrics CF6-80C engine for Boeings aircraft.
Process type Investment casting.
Material used Titanium.
Product and material
requirements and specialties
Large dimensions(52-in.dia)
Process requirements and
specialties
Capability of handling the
problems encountered in large
castings
Manual Trip
Material:Copper
aluminum
bronze
alloy.
Process: Permanent
mold casting.
CastingSupplier:
Piad
Precision
Casting
Corp.,
Greensburg,
Pennsylvannia.
Cast Component: Monocoque Scooter Chassis for Hondas Super Sport Scooter.
Material:JIS ADC12 (a 383 aluminum alloy equivalent).
Process: Diecasting.
Allen-Bradley housing
Process type
Die casting
Material used
A380 aluminum alloy
Product
and
material
requirements and specialties
1. The component needed to be sturdy
enough to withstand the outside
elements and provide easy access
to the inner drive it encased.
2. Portions of the part are visible after
assembly, making cosmetics a
consideration.
NO BAKE CASTING
BUCKET CHAIN
Material:C95410
nickel aluminum
bronze.
Process: Permanent
mold casting.
Casting Supplier:
Piad Precision
Casting Corp.,
Greensburg,
Pennsylvania.
Suspension crossmember
Material:B356
aluminum alloy.
Process:
Permanent
mold casting.
Casting Supplier:
CMI-Precision Mold,
Inc., Bristol, Indiana.
Material:535 aluminum.
Material:80-55-06 ductile
iron.
Process: Sand casting.