Implementing Advanced Technologies in the Sand Casting Supply Chain

How many castings should be poured before getting a useable part? The ideal answer may be one, but the reality is that the ideal is infrequently realized. What alloy is the part? What is its size? What is the complexity? How is the part complex: many interior cores, many thick to thin section transitions, very thin walls, or something else entirely? No two part geometries will be exactly the same, so the challenges and expectations for each part will be different. At Sikorsky, our sand cast components only seem to be getting more complex, with more demanding dimensional and metallurgical requirements. All of these factors makes the casting of these parts more challenging. This also coincides with a time where lead times and costs to develop a new casting are being scrutinized.