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Best-In-Class Manifold Body Casting


O’Fallon Casting (O’Fallon, Missouri) C355 aluminum.


O’Fallon Casting (O’Fallon, Missouri) Material: C355 aluminum


Process: In estment casting Weight: 13.5 lbs. (6.1 kg).


Investment casting 13.5 lbs. (6.1 kg)


Dimensions: 12 x 12 x 5 in. (305 x 205 x 128 mm). Application: Aircraft engine component.


12 x 12 x 5 in. (305 x 205 x 128 mm) Aircraft engine component


• The manifold casting contains se en interconnected cor passages throughout the inside of the casting, with varying diameters and depths. The combination of thin walls in some areas of the component and large masses in others, along with the grade B metallurgical requirements made this cast- hallenge and ideally suited for investment casting.





plug openings were incorporated into the design. The original design for the casting had as many as 19 openings to be welded shut prior to delivery but through design optimization, O’Fallon Casting helped the customer reduce the number of weld openings to four, saving cost and providing a more robust product.


To access the internal core passages, weld plug openings were incorporated into the design. The original design for the casting had as many as 19 openings to be welded shut prior to delivery but through design optimization, O’Fallon Casting helped the customer reduce the number of weld openings to four saving cost and pr viding a more robust product.


o access the internal core passages, eld


Magnesium Side Door Inner Panel Meridian Lightweight Technologies Inc. (Strathroy, Ontario, Canada) and General Motors (Warren, Michigan)


Material: AM60B magnesium. Process: Cold chamber high pressure diecasting. Weight: 9 lbs. (4.1 kg). Dimensions: 48 x 44.6 x 8.1 in. (1,218 x 1,134 x 206 mm).


Application: Serves as the structure of the side door and door components.


• The design was a collaboration between the diecaster and General Motors and comprises an experimental, full- header, automotive side-door inner panel.


• Magnesium diecasting in place of steel stamping contrib- uted to a weight reduction of 19.4 lbs. (8.8kg) per door and the number of parts from seven to two. It replaced 105 spot welds with 13 mechanically fastened joints.


• The required high stiffness for the structural component was achieved through holistic design of the upper half of the panel.


Acknowledgement: T is material is based upon work supported by the United States Department of Energy under Award Number DEEE005753. Disclaimer: T is report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or pro- cess disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specifi c commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. T e views and opinions of authors expressed herein do not necessarily state or refl ect those of the United States Government or any agency thereof.


32 | MODERN CASTING May 2018


The manifold casting contains seven interconnected core passages throughout the inside of the casting with var ing diameters and depths. The combination of thin walls in some areas of the component and large masses in others, along with the gr de B metallurgical requirements made this cast- ing a cing a challenge and ideal y suited for in estment casting


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