Problem Statement

In 2002 the bleed valve manufacturer contacted a new foundry about casting the valve body, because the source foundry had gone out of business.  The original casting pattern was unavailable; a new pattern was designed and produced for a first article test. 

• The new design did not produce a first article casting that met the X-ray and penetrant quality requirements. 

• Inspection of the castings showed that shrinkage porosity was developing in the heavy (1" diameter) connecting shaft between the two cylinders.

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