Simple Solutions That Work! Issue 9

BACK-2-BASICS Contact: PRABH GOWRISANKARAN [email protected] In this photo, Goleman hand coats a mold for one of 13 large and detailed torchieres for a Manhattan building that were to be cast in bronze, weighing 450 pounds apiece. Embracing newer manufacturing methods through 3D printing ended up being one of the few economic solutions for recreating originals, such as a 1904 boiler dome and drum. The boiler dome is 16 inches in diameter and the boiler drum is 28¼ inches in diameter. “In the old days they would take one-inch plate and roll it to the main curvature of the boiler drum,” explained Jason Lamontagne. “Then it would be hot flanged to take the shape of the dome. It’s a pretty complicated shape. They typically would have used a 750 ton five-post press to make that part. I understand the preservation industry in Europe has some, but there are none in this country that we know of. So it was impractical to produce the saddle using the original method, but we wanted to have an equivalent part.” Lamontagne had been following changes in the foundry industry and realized that 3D printing a sand mold might be affordable. After calling Trident Alloys, the museum had its solution. “I designed the boiler in conventional CAD and it went through the whole ASME review process. Then one of our volunteers took this particular component out, drew it as a solid model, and created a file for Trident.” From there, Trident owner Jim Galaska noted, “Trident added the solidification, printed the molds, and poured the casting.” From reproducing historical pieces to metal casting production for everyday – robotic 3D printing is proving to be an economical yet versatile method of production. 27 Metalurges of Conway, Mass. THREE. Wiscassset, Waterville, & Farmington Railway Museum (Alna, ME) At WW&F, maintaining historical accuracy is of the utmost importance, but it’s also one of the biggest challenges in keeping old locomotives running. Wiscassset, Waterville, & Farmington Railway Museum (Alna, ME)