Foundry Daily News - Topic Green Sand - Topic Lost Foam

AFS Announces Casting of the Year Winners

<font size="2">SCHAUMBURG, Ill. (USA)&nbsp;- The metalcasting industry recognized nine cast components as top designs for the 2008 Engineered Casting Solutions and American Foundry Society Casting Competition.&nbsp; The components are being used in a variety of industries, including material handling, agriculture, energy production, military, heavy truck and automotive.</font>

<font size="2"><strong>AFS awarded one overall honor, plus four Best-in-Class honors and four Honorable Mentions.</strong></font>

<font size="2">Carley Foundry Inc., Blaine, Minn., earned top honors in the annual competition for its Harley-Davidson oil tank.&nbsp; The component houses and circulates oil throughout the new Harley Rocker's operating system and is an important cosmetic item.</font>

<font size="2">Carley's component was cast in A356-T6 aluminum via semi-permanent molding; it weighs 9.25 lbs. and measures 14 x 10 x 8 in. The casting offered improved cosmetics and better heat resistance than a proposed plastic design and also beat out a multi-piece fabrication.</font>

<font size="2"><strong>2008 Best In Class</strong></font>

<font size="2">Material Handling Steering/Linkage Assembly, Piad Precision Casting Corp., Greensburg, Pa. This brass permanent mold chill casting was redesigned from a weldment composed of 10 pre-fabricated pieces, 19 weld joints and four bushings.&nbsp; The 9.82-lb. steering linkage was 10% lighter than the weldment and eliminated some machining and the need for stress relieving.</font>

<font size="2">Agri-Speed Hitch, Dotson Iron Castings, Mankato, Minn. This assembly of austempered ductile iron and ductile iron green sand castings was reverse engineered from the customer's weldment, resulting in a 30% weight reduction and 40% cost reduction.&nbsp; The agricultural hitch enables the automatic hookup and disconnection of farm equipment.</font>

<font size="2">Static Mixer Tube, Castalloy Corp., Waukesha, Wis. A highly abrasion resistant, 124-lb. white iron nobake sand casting, the part is ideal for use in the cleansing of ground coal in power generation facilities.&nbsp; The casting was converted from a seven-piece fabrication, eliminating all assembly labor and allowing for the strategic thickening of wear areas, which extends the service life of the component.</font>

<font size="2">Military Main Transmission Housing, Denison Industries, Denison, Texas. Denison converted a multi-piece assembly into this 200-lb., A356-T71 aluminum nobake sand casting.&nbsp; The conversion eliminated tubing, hydraulic lines and passageways by casting them into the design, which required 77 cores.</font>

<font size="2"><strong>2008 Honorable Mention</strong></font>

<font size="2">Volvo Multifunction Bracket/Towing Eye, Citation Columbiana, Columbiana, Ala.&nbsp; A 21-lb. ductile iron lost foam casting, the part eliminated the machining and heat treating required on previous brackets.&nbsp; It realized a 1.5-lb. weight reduction and 35.4% cost savings with cast-in frame mounting and cross-member mounting surfaces, a tow pin receiver, holes for radiator brackets and bumper bracket attachments.</font>

<font size="2">Horsepower Freaks Intake Manifold, Trilore Technologies Inc., Alamo, Calif.&nbsp; The metalcaster employed a proprietary rubber-plaster mold process to produce this 13 lb., highly polished A356-T6 aluminum conversion from plastic.&nbsp; The manufacturing method, known as the ME process, is capable of producing thin-walled castings with tight grain structure.</font>

<font size="2">Cadillac CTS Engine Cradle, General Motors Corp. and Diversified Machine Inc., Warren, Mich.&nbsp; The 33.5-lb. vacuum riserless/pressure riserless casting was poured in A356 aluminum and welded to four aluminum extrusions to form the engine cradle for a Cadillac. It reduced mass by 40% and consolidated 32 parts to one from a previous steel design.</font>

<font size="2">Rear Motorcycle Frame, Eck Industries, Manitowoc, Wis.&nbsp; Eck Industries utilized the ablation process to make this 4.9-lb. A356-T6 aluminum part with enhanced mechanical properties in its thin sections. The component, which fits on the tail section of a Buell Motorcycle Co. bike, saved weight and cost by incorporating the motorcycle's shock mount location.</font>

<font size="2">This year's Casting Competition was sponsored by MAGMA Foundry Technologies, Schaumburg, Ill.&nbsp; MAGMA will provide Carley Foundry Inc. with a one-year license of MAGMASOFT software, including training and implementation assistance.</font>

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