Digital Transformation of a 6000-Year-Old Process

Integration of advanced technologies in the casting commodity through digital transformation efforts is essential to future success of rotorcraft transmission castings. This paper reviews the advanced technologies that have been integrated into the casting process for transmission housings. The transformation in casting designs, solidification modeling, mold fabrication, casting techniques, thermal and mechanical post processing, inspection, and quality management are all impacted by new technologies and driven by the continued digital thread in the manufacturing process. The casting manufacturing process is 6000 years old, but the complexity of aircraft requirements and part designs has outpaced capability of standardized casting processes. Digital transformation driven technologies create repeatable processes that reduce production scrap and development lead times.