Innovations in Casting Design Recognized in North American Competition

DES PLAINES, Ill., May 29, 2003 -- Fifteen casting designs -- for industries as varied as automotive, aerospace, construction and agriculture -- earned "Industry Best" status at the 107th American Foundry Society (AFS) Casting Congress in Milwaukee. The 2003 recipients represented nearly all of the major casting processes and metal groups.

In addition to total cost reductions, these award-winning designs delivered significant improvements in: speed to market, design flexibility, weight and dimensional tolerances.

2003 Casting of the Year

Hitchcock Industries, Inc., Minneapolis (Strut Fan Cowl Support Beam for the Boeing 737): Cast with 0.08 in. minimum wall thickness, the one-piece aluminum alloy component replaced a fabrication of 11 aluminum parts at a 50% cost savings and a 78% reduction in assembly time. In addition, the redesign eliminated 17 shims, 175 fasteners, 40 linear ft of fillet sealant and 21 joints. The 41-in. casting weighs just 23 lb.

In application, the safety-critical casting is installed in the forward portion of the strut structure on Boeing's 737 aircraft. Functionally, it supports the fan cowling, which shrouds the engine, and houses a densely packed array of system connections between the strut and the engine.

Judges' Comments on the industry's top casting of 2003 included: " ... highly engineered quality meeting strict test requirements ... a spectacular example of part consolidation ... outstanding benefits to the customer ... a top component that proves the case for other conversions."

2003 Best in Class

Intermag-Modelex, St. Nicolas, Quebec, Canada (Multi-Function Bracket): This magnesium bracket provides numerous structural mounts and features for Ford's fuel cell electric automobile. The cast design eliminated 15 stamped steel parts used in comparable designs. The 11-lb component also provides increased dimensional integrity and structural stiffness, heat dissipation and non-magnetic properties.

Meridian Technologies, Strathroy, Ontario (Front End Support Assembly for the Ford F150 Truck): The auto industry's first magnesium structural exterior body component, this one-piece, magnesium casting was converted from 21 previously assembled stamped steel components. Now weighing 13 lb, this conversion saved 22 lb. In addition to avoiding $7 million, Ford saved millions more in assembly costs due to its ability to meet extremely tight vehicle packaging requirements.

John Deere Foundry, Waterloo, Iowa (Housing for John Deere's 9000 Series Tractor): Converted from a weldment, the redesign to a 847-lb ductile iron casting resulted in a 28% cost savings. Further, additional strength to the component was "designed-in" in the event that future applications would require higher horsepower and loads. The casting also provides a significant aesthetic improvement.

General Motors [Inline 4 Automotive Engine Cylinder Block (Defiance, Ohio) and Head (Massena, N.Y.]: This A356 aluminum engine cylinder block (74.5 lb) and head (37.5 lb) are used in the award-winning Vortec light truck engine. Designers were able to "cast-in" numerous features not otherwise possible in a single manufacturing step. The automaker saved $14.4 million in capital equipment as well as a $2.1 million annual manufacturing savings. The block and head designs have allowed the engine to achieve 20 more horsepower, while also achieving 90% peak torque.

Ohio Aluminum Industries, Inc., Cleveland (Electronic Valve Housing for a Hamilton Sundstrand Aircraft Control System): The complex part was redesigned from machined billet to a one-piece aluminum casting at a reduced weight and cost, with a far more "envelope-efficient" design. The 21-lb casting incorporated hydraulic plumbing holes, eliminating numerous drilled and pin- plugged holes.

Smith Foundry Co., Minneapolis (Drive Wheel for a Toro Utility Loader): Originally an 84-piece steel assembly, this track system drive wheel component was redesigned to a single 21-lb casting at a 15% weight reduction and a 55% cost reduction ($190,000 annually). In addition to improved wear, durability and appearance, the ductile iron component eliminated 30 min of assembly time.

Intermet Decatur Foundry, Decatur, Ill. (Rear Control Arm for the Ford Mustang Cobra): Originally conceived as an aluminum or forged steel part, the design of this safety-critical support as a ductile iron casting (8.5 lb) provided a 10%-plus weight savings and design (shape) flexibility over steel.

Aristo Cast, Inc., Almont, Mich. (Telescopic Trailer Tow Mirror Mount): Just four weeks after receiving the design, 245-gram magnesium castings were delivered to Schefenacker Vision Systems. In addition to tight delivery and tolerance requirements on this pickup truck application, the casting has thin- walls ranging from 0.06-0.12 in. Magnesium saved 3 lb vs. aluminum.

Diversa Cast Mfg., Guelph, Ontario (Automotive Pressure Manifold): By redesigning to an aluminum casting for this hybrid fan drive component, a stainless steel tube was eliminated, reducing both weight and machining/assembly time. Cast with walls as thin as 4 mm, the 7 lb component has 13 interconnected passageways (one with four 90-degree turns) that allow for improved flow in application.

Honorable Mentions

Five honorable mentions were also awarded to: Farrar Corp., Norwich, Kan. (gear axle/hub for Walker Mfg); Hayes Lemmerz International, Montague, Mich. (crossmember for Ford luxury vehicles); Kurdziel Iron of Rothbury, Rothbury, Mich. (injection molding end housing for Van Dorn Demag); Morris Bean & Co., Yellow Springs, Ohio (tire mold segment); and Piad Precision Casting, Greensburg, Pa. (railroad motor adapter frame).

Additional information and high-resolution digital photos for each award recipient is available.