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Honorable MentHonorable Mentionion Torque Rod AAM Columbiana (Columbiana, Alabama)


Material: 65-45-12 ductile iron. Process: Lost foam casting. Weight: 16.5 lbs. (7.5 kg). Dimensions: 13 x 11 x 6 in. (330 x 279 x 152 mm). Application: Rear axle lateral support for heavy truck for Volvo-Mack.


• Designing the torque rod for lost foam casting led to a 42% weight reduction and 45% cost reduction for the customer. The final design is completely as cast and eliminated extensive machining.


• The highly optimized casting design yielded multiple general 7-mm wall sections and isolated 6-mm wall thicknesses.


• Because of the weight reduction, the casting is lighter and easier for an assembler to manipulate. The con- toured geometry allows for component articulation producing clearance that eases the assembly process.


On-site Cube Camera Aristo-Cast (Almont, Michigan)


Material: AZ91E magnesium. Process: Investment casting. Weight: 0.08 lbs. (35 grams).


Dimensions: 3 x 2.5 x 2 in. (75 x 64 x 50 mm). Application: Provide video, audio and optical thermal imaging for Librestream.


• Originally a machined aluminum component, con- verting to magnesium investment casting saved 0.05 lbs. (22 grams), which was important because it is a handheld device. Magnesium also has better thermal properties and damping properties.


• The material changes allowed the customer to enter another market for the product, which is used as a hand-held or hands-free camera for onsite inspection of rugged environments.


34 | MODERN CASTING May 2018


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