Patriot Foundry & Castings Reduces their Scrap Rate by 98% with ESI ProCAST
ESI understands our industry and its unique issues. Consequently, they quickly came to terms with the limitations in the changes we could make to the matchplate configuration. Together, we were able to work within those constraints to solve the problem successfully.
A late stage customer requirement for a near perfect cast finish on a military service Nickel-Aluminum-Bronze gearbox required an upside down pour resulting in an initial 50% scrap rate due to shrinkage porosity defects that only showed during final machining.
Numerous changes to every feature of the mold, from runners to risers, were attempted causing the shrinkage porosity defects to relocate frustratingly to other areas of the cast gearbox.
Next, Patriot brought ESI ProCAST software into the process to model the pour leading to a 98% reduction in scrap rate and a very satisfied end customer with quality parts delivered on time.