How many castings should be poured before getting a useable part? The ideal answer may be one, but the reality is that the ideal is infrequently realized. What alloy is the part? What is its size? What is the complexity? How is the part complex: many interior cores, many thick to thin section transitions, very thin walls, or something else entirely? No two part geometries will be exactly the same, so the challenges and expectations for each part will be different. At Sikorsky, our sand cast components only seem to be getting more complex, with more demanding dimensional and metallurgical requirements. All of these factors makes the casting of these parts more challenging. This also coincides with a time where lead times and costs to develop a new casting are being scrutinized. Casting technologies have been tested on development programs at Sikorsky, including the use of simulation of the pour, digitally produced mold and low pressure casting. These technologies have shown dramatic improvements in lead time and reduced the number of pours to yield a useable part. However, there is still hesitation in promoting the use of these technologies for production parts. An engineering specification has been released that creates a process for using these new technologies for casting manufacturing. In addition to changing our own internal processes, Sikorsky is also driving change into the foundry industry as an outsider. While we have found that the use of simulation, additive manufacturing of the molds, and low pressure casting has greatly increased yields, the foundry industry has been slow to adopt these technologies. Identifying ways to influence change at existing suppliers and cultivate relationships with new suppliers has been paramount to the success of these projects. This paper explores this phenomena of cultivating change within our own company's processes and procedures and influencing change in the greater industry. We will also present reasons why programs are not buying in to using these technologies, as well as a strategy to mitigate the disinterest.
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