A Midwestern corporate-member iron foundry with a reputation for producing complex castings has been crowned winner of the prestigious 2024 AFS/Casting Source Casting of the Year competition.
St. Marys Foundry (St. Marys, Ohio) captured the overall title in this year's contest, which attracted submissions of remarkable castings from metalcasters throughout North America. All winners were selected by a blue-ribbon panel of independent judges with expertise in metalcasting design and production.
Other honorees were Meridian Lightweight Technologies, Lethbridge Iron Works Company Ltd., Impro Industries, Linamar Structures, corporate member Matthews International, Lee Brass, corporate member Amsted Rail - Granite City, and corporate member Watry Industries LLC, each recognized for their exceptional contributions to the field of metalcasting. The categories in which they won are listed below.
St. Marys' submission, a 6,600-pound ductile iron power frame, greatly impressed the judges. Operating in extremely harsh conditions, the pump for which it's designed pressurizes fluid at 15,000 psi to crack rock deep in the earth to release oil and gas. The casting replaces a fabricated weldment, increasing the part's lifecycle from 6,000 hours to more than 20,000 hours of service in the field.
St. Marys’ Casting of the Year, along with other finalists, will be showcased on the sold-out exhibit floor at Metalcasting Congress 2024. The event runs April 23 – 25 at the Baird Center in Milwaukee, Wisconsin, with the show floor open on April 24 through noon April 25. Registration is available here.
"We extend our heartfelt congratulations to St. Marys Foundry and all the finalists of the 2024 AFS/Casting Source Casting of the Year competition. Their remarkable achievements exemplify the spirit of innovation and excellence that drives the metalcasting industry forward," said AFS CEO Doug Kurkul. "We are proud to showcase their groundbreaking work at Metalcasting Congress 2024 and celebrate their significant contributions to our field."
CASTING OF THE YEAR
St. Marys Foundry, Ltd.
Location: St. Marys, Ohio, USA
Submission: Power Frame
Material: Ductile ASTM A395 60-40-18
Process: Gravity Pour - Nobake Sand
Weight: 6600 lbs.
Dimensions: 67.4 in. x 53.4 in. x 43.6 in.
Application: Frac pump frame
OUTSTANDING ACHIEVEMENT
Meridian Lightweight Technologies
Location: Strathroy, Ontario, Canada
Submission: MY2021 Acura-TLX Steering Hanger Beam (SHB) Assembly
Material: AM60B magnesium alloy
Process: High-Pressure Die Casting (HPDC)
Weight: 5.43kg
Dimensions: 34 mm. x 154 cm. x 70 cm.
Application: Provides first-rate rigidity and safety with weight reduction and energy management
BEST EXAMPLE OF A CONVERSION
Lethbridge Iron Works Company Ltd.
Location: Lethbridge, Alberta, Canada
Submission: Row Cleaner Shoe
Material: 80-55-06 Ductile Iron
Process: Green Sand (Hunter 10)
Weight: 7.3 lbs
Dimensions: Approx. 8 in. x 7 in. x 6 in.
Application: Agricultural equipment - removes debris from the seed trench while seeding
NEWCOMER OF THE YEAR
Amsted Rail - Granite City
Location: Granite City, IL, USA
Submission: GSI Transit Truck Set
Material: 2% Nickel Steel
Process: No Bake Sand – 3D Print
Weight: 3150 lbs. and 2200 lbs.
Dimensions: 56 in. x 145 in. x 26 in. and 31 in. x 117 in. x 23 in.
Application: Provides support and mobility to cars
BEST IN CLASS
Linamar Structures
Location: Fruitport, Michigan, USA
Submission: Battery Electric Vehicle Semi-Trailing Arm
Material: A356-T6 Aluminum
Process: VRC/PRC
Weight: 23.5 kg cast/19.6kg mach
Dimensions: 656.10 mm. x 724.27 mm. x 325.43 mm.
Application: Rear chassis/suspension arm
BEST PROTOTYPE OR INNOVATION
Matthews International
Location: Pittsburgh, Pennsylvania, USA
Submission: Anchor
Material: Custom Bronze Alloy
Process: Sand Casting
Weight: 14.6 lbs.
Dimensions: 20 in. x 12.5 in. x 3 in.
Application: A piece for architectural or memorial functions -- depending on customization
HONORABLE MENTION
Impro Industries
Location: Diamond Bar, California, USA
Submission: Bearing Housing
Material: Ductile Iron
Process: Green Sand Molding
Weight: 9.85kg
Dimensions: 13 in. x 10.5 in. x 5 in.
Application: Transmission system for commercial vehicles
HONORABLE MENTION
Lee Brass Acquisitions LLC.
Location: Anniston, Alabama, USA
Submission: Diversion Valve Body
Material: C89833
Process: 3D-Printed Sand Mold
Weight: 17.8 lbs.
Dimensions: 9.5 in. x 5.19 in.
Application: Used in the wastewater industry
HONORABLE MENTION
Watry Industries LLC
Location: Sheboygan, Wisconsin, USA
Submission: V12 Outboard Engine Oil Sump
Material: A356.0 - T6
Process: Reverse Tilt Semi-Perm Mold
Weight: 51 lbs.
Dimensions: 23 in. x 18 in. x 15 in.
Application: Reservoir for engine oil
The American Foundry Society is a dynamic technical and advocacy organization that serves and represents the $50 billion metalcasting industry. AFS is the only association serving the entire industry, including all metals and processes, with a three-part focus on advocacy, education, and innovation. AFS also publishes Modern Casting and Casting Source magazines and presents Metalcasting Congress and CastExpo, the largest metalcasting trade events in North America. Founded in 1896, the organization is based in Schaumburg, Illinois, with an advocacy office in Washington, D.C. More information is available at afsinc.org.