A high-pressure, 175-psi lost-foam aluminum casting method now in operation at Mercury Castings in Fond Du Lac, WI, reduces cast part porosity to 0.003% vs. 1% for conventional lost-foam casting techniques. Mercury says the method is the first of its kind in use outside of Europe. It also doubles high-cycle fatigue strength and increases elongation from 3% to 8.2%. The technology is licensed from French aluminum company Pechiney, whose only other licensee is the German foundry company ...

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