O’Fallon Casting, in O’Fallon, MO, produced this 12x10x8-in. pump housing in C355 aluminum, achieving time and cost savings versus the fabricated version of a similar product.
“This pump housing is an excellent example of how the investment-casting process offers the versatility to consolidate a fabrication made from multiple components, made from a variety of processes, into a single piece casting,” explained Jake Robben of O’Fallon Casting.
Aero engine pump housings have complex internal passages, and are typically fabricated by combining a number of components manufactured by several processes. Using investment casting, it was possible to reduce component weight while simultaneously eliminating future failure points at the assembly location.
This casting contains multiple interconnected core passages with varying diameters and depths. Considering this with the combination of thin walls, large masses of metal and grade B metallurgical requirements, the component lends itself to the investment casting process. Through the application of this process and design optimizations, O’Fallon Casting was able to help the customer reduce the number of weld openings from ten to five, which saved the customer cost and provided a more robust product.