Case Studies

AUTOMOTIVE

Aluminum Sand Casting

356.2 sr T6 Condition

Pressure Tight Casting


CHALLENGE:

  • Create a new aluminum sand casting for building of Nitrogen-energized racing shock system for major snowmobile manufacturer.

RESULTS:

  • A 356.2 Sr modified heat treated to a T6 condition (on site).
  • Complex core geometry to complete passage.
  • 100% pressure tight casting.
  • 500 psi operating pressure.
  • Machining completed including swivel bearing installed to a .0005″ fit.
  • Anodized coating added as required.
  • Customer success was reached because of single house responsibility for casting tooling, machining an fixture building in-house then completing 4000 sets.

Nitrogen-Energized Racing Shock System

HIGH & LOW VOLTAGE APPLICATIONS

Casting in Aluminum Bronze Alloy CDA 95200

Machining: Three Planes Supporting Contacts, Mounting and Interrupter Feature

CHALLENGE:

  • Construct new casting to eliminate three previously assembled parts. Pass all design and testing criteria for current carrying casting in Aluminum Bronze Alloy CDA 95200.

RESULTS:

  • Alloy achieves excellent U.T.S. of 75,000 p.s.i. and corrosion resistance.
  • Casting Unique Parting line and outside coring.
  • Machining: three planes supporting contacts, mounting and interrupter feature.
  • Ship 150/month Cast and machined.

High Voltage Castings

HIGH PRESSURE FLUID HANDLING

High Pressure Fluid Handling Metal Casting

CHALLENGE:

  • Gravity permanent mould aluminum casting for non-drip recoupling application. Operating pressure – 250 p.s.i.

RESULTS:

  • Allow A356.2 T6 Cores accomplished as material web inside part.
  • 4 “O” ring seal surfaces .32 micro-finish or better.
  • 100% pressure tight Anodized coating applied.

High Pressure Fluid Handling

MARINE

We have been retained by a major manufacturer of marine hardware products to cast and machine 50 different products used in commercial fishing applications, including:

  • Steering systems
  • Net handling devices
  • Propeller retaining nuts

These are all manufactured in Manganese Bronze C86500 assuring highest strength and corrosion resistance in salt-water environments.

HEAT EXCHANGERS

We are in production of these 3 cast and machined and pressure-tested bronze manifolds.

These products were converted from in-house soldered fabrications. The cost savings are obvious. These items are supplied on a Kanban pull system.

PLUMBING

A major plumbing manufacturer retained us to assist in the re-engineering of a cast and machined valve body that reduced mass of the existing design by one-half pound, creating a material savings of $ 2.25 per piece. Annual usage is 100,000 pieces.

We generated prototypes and pre-production pilot runs, then took the product into full production.