Howmet Aluminum Casting. Responding to your needs for high-quality aluminum investment castings

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1 Howmet Aluminum Casting Responding to your needs for high-quality aluminum investment castings

2 You want quality aluminum investment castings Howmet Aluminum Casting has manufacturing facilities in three countries and is the world s largest aluminum investment casting supplier. Our customers include aerospace, defense, performance racing, medical as well as numerous other commercial and industrial markets. We supply the highest quality investmentcast parts for a broad range of applications. Aluminum investment castings offer our customers a way to reduce cost by converting multiple parts into single-piece structures. In addition, complex design features can be incorporated, also allowing cost savings over alternative, competitive processes. To maximize your savings, involve Howmet Aluminum Casting at the early stage of new part development. Concurrent engineer your product using our technical people and accelerate your time-to-market. Howmet has installed the most effective quality systems in the aluminum investment casting industry. Converting a fabricated assembly to a casting enables cost savings from the initial design phase through the final production piece. We specialize in reducing production costs for original equipment manufacturers by converting expensive fabricated assemblies into more affordable single-piece, lightweight, high-strength, often complex aluminum investment castings. Howmet has the improved quality systems, advanced process controls and facilities to align our capabilities with your needs. By eliminating sub-assemblies and secondary machining operations, the aluminum investment casting process has been of great benefit to industry. Housings can either be simple or complex, and can be designed to incorporate extremely fine details, such as connector Quality Assurance ISO9001 Certified AS 9000 Certified D Certified Alcoa Business System

3 You want the most advanced casting capabilities at your service Quality Philosophy We are committed to providing products and services of the highest quality and reliability, in total conformance with customer requirements. A core focus throughout Howmet Aluminum Casting is to continually improve process performance. Design engineers take advantage of investment casting s ability to produce complex shapes and intricate features. Howmet is ISO Certified, and all special processes are approved to NADCAP standards. Howmet also utilizes an internal peer audit system and an independent third party to monitor Quality Assurance compliance. Our facilities are approved by all major aerospace and defense contractors, and a variety of customers servicing commercial and industrial markets. Howmet s Quality Manual The Howmet Quality Manual ensures the highest level of quality company-wide. Our manufacturing facilities are approved to manufacture to exacting commercial aerospace and defense standards. This technician prepares a casting for inspection. Howmet utilizes coordinate measuring machines and other measurement devices to accurately verify physical dimensions. Our engineering departments can interpret Catia, Unigraphics and Pro- Engineer CAD files. The investment casting process provides our customers with a cost-effective method to manufacture complex geometry plus the benefits of excellent physical properties and dimensional consistency. NADCAP Special Process Certifications NDT Heat Treatment Materials Welding 1

4 > You want component affordability Value Today engineers take advantage of the investment casting process to design onepiece, near-net-shape, complex components. Selecting the investment casting and datum pads, to mention only a few cast-in features. This capability helps remove design barriers, improve product performance and trim cycle times. process as a production strategy generates significant cost savings. The result is greater competitiveness for OEMs that convert to investment castings First, consolidation of multiple details into and leverage the process s ability to cut a single piece capitalizes on investment costs and reduce time-to-market. casting s ability to convert numerous part numbers into a single assembly, Howmet Aluminum Main Flap Torque Fitting eliminating administrative, handling and inspection tasks. The most valuable product is the one that gets to market fastest and outperforms the competition. Second, near-net-shape castings require a minimum of machining and assembly, reducing operating expenses such as those associated with labor, floor space and materials. Third, complex components can be produced with thin- or thick-wall sections, intricate passageways, sculpted surfaces 7055 Hogouts D357 Casting 30% Growth in stress carrying capability 125% Additional casting (safety) factor 15% Weight savings per ship set 80% Cost savings per ship set The table illustrates typical tolerance requirements. The vertical column indicates the tolerance requirements, while the horizontal column indicates the longest distance from the datum point. Contact your Howmet representative for your specific design needs. Complex, asymmetrical, cored shapes now present fewer challenges to the aluminum investment casting process. 2

5 > You want to streamline time-to-market Stereolithography (SLA) QUICKCAST enables customers to prove out designs before committing to hard tooling. It is not uncommon for customers to use SLA for low-quantity production runs. Consult with Howmet engineering to create the ideal casting design and streamline the entire process. Optimal savings are gained by utilizing aluminum investment castings as your baseline process. Finish-to-Print Capabilities Machining Anodizing Painting Assembly Kitting Other value-added services Howmet has the technology necessary to receive your designs electronically via multiple formats such as Catia, Unigraphics and Pro-Engineer, eliminating administrative, handling and inspection costs. Howmet offers machine to print, painting and assembly for those customers who wish to reduce costs commonly associated with outsourcing. This provides you with the ability to purchase a finished assembly and the benefits of a reduced supplier base. 3

6 Leading You want to put world-class technology to work for you Howmet provides the customer with casting design assistance options. Howmet is the exclusive licensee of the Sophia controlled solidification process in North America. With advanced foundry techniques and equipment, we can offer customers mechanical properties not available by conventional means. To find the right solution for your casting design, contact Howmet, an experienced leader in investment casting. Howmet offers effective solutions for your investment casting Aluminum-Base Alloys Spec Minimum Tensile Properties Alloy Preferred Applicable Ultimate Yield Elongation Designation Temper Specifications (ksi) (ksi) (%) needs. A357 T6 AMS-A T6 AMS F357 T6 AMS Comments: Moderate to high strength, excellent castability, weldability and pressure tightness; strengths near maximum may require controlled solidification processing. Applications: airframe structural and engine components. D357 T6 AMS E357 T6 AMS Comments: Superb static and dynamic properties for critical applications when combined with controlled solidification processing. A356 T6 AMS-A T61 AMS T6 AMS T6 ASTM-B Comments: Moderate to low strength, excellent castability, weldability and pressure tightness. Applications: housings, chassis, castings requiring fine detail. C355 T6 AMS-A T6P AMS This diffuser significantly reduced inspection, machining and assembly requirements on the OEM s shop floor. Applications: components exposed to moderate temperatures, such as turbine engine parts, pumps, etc. A201 T7 AMS-A T7 AMS Comments: Design only in consultation with the foundry. Applications: high strength castings. Excised specimens: actual strength and elongation results from castings are part geometry specific; CONSULT WITH FOUNDRY. Not limited to only these specs. Reduced Beryllium specifications (20 ppm max). 4

7 VISION Howmet Castings, an Alcoa business, is a values-based world leader in high technology castings and related businesses. We are dedicated to creating exceptional value for customers, shareholders, employees and the communities where we operate. Our global strategy is based on profitable growth, operational excellence and market leadership.

8 Bethlehem Casting 2175 Avenue C Bethlehem, PA Phone: Georgetown Casting 93 Mountainview Road North Georgetown, Ontario L7G 4J6, Canada Phone: Laval Casting 4001 Autoroute des Laurentides Laval, Quebec H7L 3H7, Canada Phone: Howmet-Ciral snc Sales Office Immeuble le Richelieu 21, rue des Trois Fontanot Nanterre Cedex France Phone: 33 (0) fax 33 (0) Plant and Main Office Zone de la Presaie B. P Evron Cedex France Howmet Corporation, 2002 Howmet Castings 6450 Rockside Woods Boulevard Suite 350 Independence, OH USA