2008 AFS/ECS casting competition: Carley Foundry's shiny blue oil tank took home this year's prize for Casting of the Year, but not just because it was pretty

Modern Casting, May, 2008

* By carefully positioning cores in metal dies, the part achieved 0.16-in. wall thicknesses, providing a weight savings of 2.2 lbs. over previous designs and making welding easier.

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Horsepower Freaks Intake Manifold

Trilore Technologies Inc., Alamo, California

Material: A356 aluminum with T6 heat treat.

Process: Rubber-plaster mold ME process.

Weight:. 13 lbs.

Dimensions: 28 x 18 x 7 in.

Application: Auto aftermarket intake manifold.

Converted From: Plastic.

* The highly polished aluminum automotive casting weighs 13 lbs. and was converted from plastic, increasing efficiency and power.

* The refined rubber-plaster mold ME process produced a thin-walled casting with tight grain structure, allowing the part to pass pressure testing and improving surface finish.

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Rear Motorcycle Frame

Eck Industries, Manitowoc, Wisconsin

Material: A356 aluminum with T6 heat treat.

Process: Ablation sand process.

Weight: 4.9 lbs.

Dimensions: 10 x 8 x 6 in.

Application: Motorcycle frame and mounting locations.

* The aluminum part, which fits on the tail section of a Buell Motorcycle Co. bike, saved weight and cost by incorporating the bike's shock mount location.

* The part achieves enhanced mechanical properties in thin sections through the ablation process, which cools the casting rapidly to produce a tight microstructure.

Visit www.moderncasting.com to view an online photo gallery of the casting of the year winners.

A MODERN CASTING Staff Report