Application of Casting Technologies to Sikorsky Development Programs

Sikorsky Aircraft Corporation recently demonstrated new casting technologies in two if its latest development programs, the S-97 RAIDER™ aircraft and Future Advanced Rotorcraft Drive System (FARDS), to improve casting quality and speed to market. The development of new sand castings for rotorcraft gearbox housings can frequently take years to complete. Using modeling and simulation, additive manufacturing of the mold, and low pressure casting, Sikorsky has shown that the lead time and number of pours to yield a usable casting has been reduced by at least ten times compared to using traditional casting methods. These technologies also reduce the amount of weld repair required. Ultimately this will allow for new and improved gearbox designs with better speed to the market.