Machine Design

AFS Castings of the Year

The metalcasting industry handed out top honors in its 2008 Engineered Casting Solutions and American Foundry Society Casting Competition.

The winners serve in a variety of industries, including material handling, agriculture, energy production, military, heavy truck, and automotive.

Carley Foundry Inc., Blaine, Minn., took Casting of the Year honors for its Harley- Davidson oil tank. The tank was cast in A356-T6 aluminum via semipermanent molding; it weighs 9.25 lb and measures 14 10 8 in. The casting is better looking and increases heat resistance compared to an alternative plastic design and a multipiece fabrication.

A brass permanent-mold chill casting for a steering linkage from Piad Precision Casting Corp., Greensburg, Pa., was redesigned from a weldment composed of 10 prefabricated pieces, 19 weld joints, and four bushings. The resulting 9.82-lb component was 10% lighter than the weldment and eliminated some machining and the need for stress relieving.

For its Agri-Speed Hitch, Dotson Iron Castings, Mankato, Minn., engineered an austempered ductile-iron and ductile-iron green-sand casting from a weldment. The new assembly was 30% lighter and cost 40% less.

In a Static Mixer Tube, Castalloy Corp., Waukesha, Wis., made an abrasion resistant, 124-lb white-iron no-bake sand casting of a tool for cleaning coal in power-generation facilities. It was converted from a seven-piece fabrication, eliminating assembly and allowing for thickening in wear areas which extends the service life of the component.

Denison Industries, Denison, Tex., converted a multipiece assembly into a 200-lb, A356-T71 aluminum no-bake sand casting. The conversion eliminated tubing, hydraulic lines, and passageways by casting them into the design, which required 77 cores.

Citation Columbiana, Columbiana, Ala., devised a 21-lb ductile-iron lost-foam casting that eliminated machining and heat treating needed on previous towing brackets. The new part is 1.5-lb lighter and saves 35% of the costs associated with the previous one. The new part has cast-in frame mounting and cross-member mounting surfaces, a tow pin receiver, and holes for radiator and bumper brackets.

Diversified Machine Inc., Warren, Mich., created a 33.5-lb vacuum and pressure riserless casting poured in A356 aluminum. It is welded to four aluminum extrusions to form the engine cradle for a Cadillac. It reduced weight by 40% and consolidated the previous steel design’s 32 parts into one.

For its Rear Motorcycle Frame, Eck Industries, Manitowoc, Wis., used ablation to make a 4.9-lb A356-T6 aluminum part with enhanced mechanical properties in its thin sections. The component, which fits on the tail of a Buell Motorcycle Co. bike, saves weight and cost by incorporating the motorcycle’s shock mounts.

For more information on the competition, contact Dave Krugman, AFS, at [email protected] or 847/824-0181.

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