* This component was originally designed as a part machined from billet and took advantage of the V-Process
attributes to convert it to a casting.
provides a multitude of casting services specializing in aluminum V-process
is the least common process, but an additional facility was reported this year, taking the total from seven to eight.
From the first Casting of the Year--the lost foam cast aluminum oil filter/cooler adapter for Mack Trucks--to the V-process
cast steel crawler transporter's tread belt shoe for NASA that won in 2005 to last year's ablation sand cast aluminum space frame nodes for Honda, our winners have showcased the diversity and ingenuity of metalcasting's capabilities.
Seven facilities reported using the V-process
, a casting method with a vacuum holding unbonded sand in a mold during pouring.
GREEN SAND, NOBAKE TOP PROCESSES Green Sand/Horizontally Parted 655 Nobake 604 Diecasting 352 Gas Hardened/Coldbox 273 Investment 255 Green Sand/Vertically Parted 208 Permanent Mold, Gravity Tilt/Pour 198 Shell Mold 148 Permanent Mold, Low Pressure 94 Centrifugal 85 Squeeze/Semisolid 82 Plaster Mold 52 Lost Foam (EPC/Full Mold) 47 Continuous 23 V-Process
7 The total numbers for facilities using each process remained relatively stable compared to 2013.
Research work included real-time energy use data collection on a V-process
vacuum casting system, measurements in the melt systems at that facility, and measurements in the melt, molding and finishing systems of a nobake ductile iron casting facility.
Honorable mentions in the contest include Larry Glosch and Jonathan Giove, Western Michigan University, Kalamazoo, Mich., for their paper "Shell V-Process
," and Dimitrios Kotsakis, Mohawk College, Ontario, Canada, for his paper "Feasibility of Investment Cast RF (Radiofrequency) Load Housing with Integral Silicon Carbide (SiC) Absorber Element."
With capacity booked solid for the near term, every employee in the V-process
casting facility; in each of its three shifts, has plenty to do to meet delivery deadlines.
The facility employs green sand molding on squeezers (10% of production is green sand) for a few low running aluminum jobs, for its copper-base business, and to produce chills for the aluminum nobake and V-process
Green Sand/Horizontally Parted 659 NoBake 613 Pressure Diecasting 354 Gas Hardened/Coldbox 313 Investment Casting 299 Green SandNertically Parted 228 Permanent Mold-Gravity/Tilt Pour 194 Shell Mold 149 Permanent Mold-Low Pressure 101 Centrifugal 94 Vaccum Casting 84 Squeeze/Semi-Solid 82 Plaster Mold 56 Lost Foam (EPC/Full Mold) 41 Continuous 24 V-Process
7 While most facilities report using multiple processes, the horizontally parted green sand process is the most popular.
Nobake 629 Centrifugal 92 Continuous 27 Pressure Diecasting 369 Coldbox 324 Horizontal Green Sand 670 Vertical Green Sand 232 Investment Casting 226 Lost Foam Casting 44 Gravity Permanent Mold 196 Low Pressure Permanent Mold 102 Plaster Molding 62 Shell Molding 147 Squeeze/Semisolid Casting 78 Vacuum Casting 89 V-process
7 1,644 Metalcasting Facilities Note: Table made from bar graph.