a.w.bell – journey to aerospace - airshow... · • cad/cam c. 1990 • soon integral to tooling...

A.W.Bell – Journey to Aerospace

Jason BarklaDip(CompetMan), GradDip(CAD/CAM), BTech(IndDes), MMultimedDes

Business Development Manager - A.W.Bell Pty Ltd

AW Bell The Casting Specialists Home of the ABE Casting Process

Introduction

• A.W.Bell Background and Innovation

• A.W.Bell and the Need for Transformation

• The Transformational Journey Begins

• Additive Manufacturing + ABE Casting

• Leveraging the power of Innovation

• A.W.Bell Now, the Journey ContinuesAW Bell The Casting Specialists Home of the ABE Casting Process

A.W.Bell’s Plant in Dandenong South, Victoria


A.W.Bell Background

• Founded in 1952 as pattern-maker

• Added tooling, post-machining and sandcasting - 1972

• Transformed into an investment casting foundry - 1982

• Additive Manufacturing established in 2000

• ISO9001 and ISO14001 accredited

• Automotive, medical, general castings, some defenceAW Bell The Casting Specialists Home of the ABE Casting Process

Investment Casting Process


Sand Casting Process


• Specialise in critical duty product

• Complex parts with many features and undercuts

• Enormous range of alloys ferrous and non-ferrous– Aerospace grade and other aluminiums– Super Duplex and other stainless steels– High tensile, low alloy and high alloy steels– Various bronzes– Virtually any air-melt high-performance metals

A.W.Bell and Casting


A.W.Bell Product


Thales


Marand


Milspec Manufacturing

Nulka, ship decoy missile

Cable entry housing

Pivot plate


W&E Platt

AW Bell have supplied


• CAD/CAM c. 1990

• Soon integral to tooling manufacture

• Specialising in complex shaped dies and tools

• Sophisticated pattern manufacture for auto industry

• Feeds in to all aspects of our processes

A.W.Bell and Innovation


• Rapid Prototyping in 2000

• Over 1000 projects and many 1000s of parts

• Specialising in complex metal products and prototypes

• Additive Manufacturing with investment casting

• Many parts in heavy-duty end-use applications



• Casting simulation in 2005

• Successfully implemented across 100s of projects

• Very accurate predictor if used properly

• Indentifies shrinkage and flow problems

• Perfect R&D tool for process improvement



A.W.Bell and the Need for Transformation

• From 2005 declining demand for tooling and product for automotive and other commodity industries

• One of several investment casting foundries in the region

• GFC in 2007-2008 saw the business contract

• Increasing loss of products to off-shoring

• Time to embark on a transformative journey


The Transformational Journey Begins

• Redefining the vision

• Lean training from top to bottom

• Building and strengthening networks and reputation

• ABE casting process

• Lifting quality standards


• Transform A.W.Bell into a supplier of complex metal components with high mechanical properties, into the defence and aerospace sectors.

The Transformational Journey Begins -Redefining the Vision


• All employees were trained in lean and awarded certificates and diplomas in competitive manufacturing.

The Transformational Journey Begins -Lean training


• A.W.Bell is active in regional organisations and well engaged with governments

• 2011 Inducted to Victorian Manufacturing Hall of Fame• 2011 Young Enabling Technology Entrepreneur - Agnel

D’souza• 2013 Medium-sized Manufacturer of the Year• 2013 Young Engineer of the Year - Stephen Murtagh• 2014 Lifetime Achievement Award - George Hellyer• 2014 Vic Professional Engineer of the Year - Dr Roger

Lumley

The Transformational Journey Begins -Networks and Reputation


• Advanced investment casting process

• High strength, high quality

The Transformational Journey Begins -Aluminium Billet Equivalent (ABE) Casting Process


• Pursued and gained AS9100C accreditation

• Cultural shift required throughout organisation

The Transformational Journey Begins -Lifting Quality Standards


37

New capability & capacity includes

Shell Oven Assisted Pouring Arm

Spectrometer

FPI X Ray Heat Treatment


• A.W.Bell has developed a world leading casting process called ABE (Aluminium Billet Equivalent)

• Developed for Aerospace application

• High strength and high density parts

• Allows sophisticated geometries that cannot be cost effectively machined from billet

Additive Manufacturing + ABE Casting Process


• Additive Manufacturing supports complex shapes

• Quick turnaround of patterns, perfect for R&D

• Dimensional accuracy and stability

• Removes the need for very expensive and complex CNC cut aluminium tooling

• Proof of concept for conservative sectors



• Complex cast component suffering failures

• R&D program as fee for service

• Project deepened the rapport and trust with customer

• Tooling ordered and FAI parts in production

• Significant amount of other work now secured

Leveraging the Power of Innovation -Defence Project


2015:Tier 1: 7 parts in production

4 parts in development1 X Tier 1 assembly

In Cast Iron and Aluminium

(Cast, Machined, Painted, Assembled at AWBell.)

Tier 2: 5 partsIn Aluminium Bronze and Aluminium

(Cast at AWBell, some machined)

2012: R&D program on advanced ferrous castings begun

Defence Project:ASC : Collins Class Sustainment

Source: wikipedia

AW Bell The Casting Specialists Home of the ABE Casting Process AW Bell The Casting Specialists Home of the ABE Casting Process

• Significant progress made in the last 5 years

• Accredited aerospace supplier to companies such as Raytheon, BAE Systems, Northrop Grumman

• Continuing drop-off in traditional product and markets

• Numerous foundries closed throughout the region

• Growing order base and interest from local and export customers

A.W.Bell Now, the Journey Continues


Thank You for your timeJason Barkla

Business Development Manager

A.W.Bell Pty Ltd


a.w.bell – journey to aerospace - airshow... · • cad/cam c. 1990 • soon integral to tooling...

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