AFS Announces 2009 Casting of the Year Winners
Craft Pattern & Mold Inc.,
Craft Pattern & Mold’s component was cast in A356 aluminum with T-6 heat treatment via nobake sand, weighs 51 lbs. and measures 12 x 18.75 x 45.5 in. Structurally, the cast frame is more rigid and precise in shape and form than the original fabricated steel frame and offers reduced dimensional variation.
AFS also awarded four Best-in-Class honors and four Honorable Mentions. Following is a look at each of the award-winning components.
2009 Best In Class
Refueling Manifold, Alum-Alloy Co. Inc.,
Cam, Signicast Investment Castings,
ClassicSeries CVR Dental Pump, Piad Precision Casting Corp., Greensburg, Pa. The dental suction pump’s casting design features cast-to size holes, diameters, and internal ports and passages. Some internal passages and overflow ports could not be formed through the extraction of steel cores, so the casting supplier used two expendable sand cores. The casting design also incorporated three mounting feet into the housing, which reduced the net casting weight by 7% and overall cost by 14% compared to purchasing the housing and mounting base plate separately.
Agriculture Hitch, Bremen Castings Inc.,
2009 Honorable Mention
Aerospace Valve, Aristo-Cast Inc., Almont, Mich. The 770g valve was made for the aerospace industry. To fully understand the complex core geometry of the 3 x 4 x 2-in. part, the casting supplier produced cores using fused deposition modeling. These models helped the casting engineers spot trouble areas that would require special attention. A low pressure semi-pneumatic device was used to fill the core passageways and eliminate air pockets that could cause core breakage or failure. The finished castings were checked via x-ray for core breakage.
Snubber Arm Casting, P&H Mining Equipment,
Wind Power Tail Fin, LA Aluminum Casting Co.,
U.S. Military Target Location Device, Precise Cast Prototypes & Engineering, Commerce City, Colo. This magnesium part helps acquire and locate targets for the defense industry. Using magnesium castings shaved months off development, reduced overall cost, and provided superior electromagnetic interference reduction, which is significant for electronic enclosures. The casting supplier had to overcome thick sections surrounded by thin areas. Some cross sectional thicknesses are as little as 0.04 in.
This year’s Casting Competition was sponsored by MAGMA Foundry Technologies,
SOURCE American Foundry Society