Utilizing Casting Technologies on Legacy Part

Sikorsky has developed a specification outlining the use of three casting technologies: simulation, additive manufacturing of the mold and low pressure casting. This specification has been used in the past on new development projects with positive results, reducing lead times and number of pours to produce a useable part. When the S-92 program needed to develop a second source for a casting, they worked with Magellan Aerospace to implement the specification. The project proceeded on time with all castings able to be used. Some elements of the specification were modified to work with a legacy part design, including the use of statistical process controls to reduce variability in crucible pouring.