Consolidated Casting Success Stories

Combustion Assembly

The combustor assembly is a critical part of the microturbine power generator for the Parallon 75. The original component consisted of 16 individual machined tabs that were electron beam-welded in 64 places onto a fabricated tube.

With turnkey responsibility for the complete combustor assembly, Consolidated Casting Corporation produced the tabs as a single ring casting which becomes two finished rings when split in a secondary machining operation.

Each finished ring component is butt-welded into a 0.080 in. wall sheet metal tube, as opposed to the individually welded tabs of the original design.

The foundry also assembles the complete combustor assembly, which includes five investment castings, sheet metal tubes, a machined pin, stampings, tubes and fittings.

The change in design reduced the sub-assembly time by 26 minutes and achieved a greater than 50% per-part cost reduction.

Water-Cooled Manifold and Cover Assembly

Originally designed by the customer and their original supplier as a 2-piece investment cast manifold and cover assembly (top view), welded together by an outside sub-contractor and machined and pressure tested by a third party, resulting in a multitude of quality and delivery issues and finger pointing throughout the supply chain. The customer decided to look for a new supplier that could produce the entire assembly in house, in order to eliminate the problems in the supply chain.

Consolidated Casting Corporation (CCC) accepted the challenge to produce the complete assembly in house as it was originally designed, while it's engineers helped develop a new, much more efficient, higher quality design (bottom view). CCC's change to the new design incorporated a lower cost stamping in place of the cast cover, reduced the weight and cost of the (stainless steel) assembly, improved the stability, weld ability and quality of the product, reduced lead times and inventory, and ultimately saved it's customer more than $300,000.00 per year in production costs. The components are cast, robotically welded, CNC machined and 100% leak tested at CCC.

Reduce 'Total Cost' Via Investment Casting's Near-Net-Shape Components

This single piece was converted from a multi-component, screw machined, weld assembly to a single piece investment casting. The new design reduced customer cost and improved performance.

Consolidated Casting Corporation Converts A 3-Piece Powder Metal Assembly Into A 1-piece Investment Casting

Consolidated Casting's creative design engineers helped its customer to convert this three piece (shown on left) powdered metal assembly into a one piece (shown on right) investment casting, which greatly reduced cost and improved product quality.

Consolidated Casting Corporation Casts 'Uncastable' Valve Components To Produce Complex Attenuator Casting

The original assembly was thought to be uncastable, until Consolidated Casting's creative engineers got together with the customer to develop and produce this investment casting.