FOND DU LAC, WI — A high-pressure, 175-psi (12-bar) lost-foam aluminum casting method now in operation at Mercury Castings here reduces cast part porosity to .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 the French aluminum company Pechiney, whose only other licensee is the German ...

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