Case study: JLR Transcend program 20th March 2020 | Case Story Transcend Transmission Assy Finecast Foundry Ltd have developed a gearbox consisting of 5 main castings and fragile internal cores printed using cerabead to offer a more robust solution Component Gearbox assembly for the automotive sector, in A356 aluminium alloy, consisting of five main castings, each with very high dimensional tolerances. Challenges Complex internal core geometry, with risks of gas being trapped during casting and core cracking. High internal core dimensional accuracy required. High casting integrity requirements. X-ray inspection: AMS STD 2175 Class 1 Grade C. Casting to resist leak testing confirmed by pressure testing to 20 Bar. Method Close collaboration with customer to optimise design for casting with additional bosses to provide core support. Casting simulation used to confirm filling geometry, reduce liquid metal turbulence and optimise methoding design to reduce risk of shrinkage porosity. Chemically bonded sand casting used to produce casting mould. Cerabead cores used to reduce risk of core cracking during casting and optimise dimensional control. Cores design with small vents to reduce risk of gas entrainment. 3D printed cores to increase strength and steel guide pins employed to minimise assembly variability. GOM scanning of mould and core assembly prior to casting to ensure mould accuracy. HIPping of casting completed prior to pressure testing to 20 bar. Visual and full NDT inspection to ensure customer specification achieved. Related Case Studies View all Case study: JLR Transcend program JLR Transcend program was complex multi core assembly. Case study: Large Lightweight Stabilised Antenna Platform Main Frame This was a Lightweight Stabilised Antenna Platform for a military application Our Technical Partnerships As an industry leader, we pride ourselves on shared engagement with world class foundry and advanced Technology research centres and Universities. What we do About us Product Gallery News & Case Studies Careers & apprenticeships Contact us Contact +44 (0) 1903 716471 enquiries@finecast.co.uk Finecast Foundry Lineside Way, Littlehampton, West Sussex, BN17 7EH United Kingdom Company Number: 04528905 Customer terms & conditions | Supplier Terms & Conditions © Finecast Foundry 2020 | All rights reserved | Website by Molokini Marketing