1. Reproduction of Tractor Components Senior Design Project Spring ‘07 Charlie Tullis

2. Part #One: Exhaust Valve Cage  1914 McCormick 8-16 Mogul Tractor  Problem: Customer missing part

3. Part #One: Exhaust Valve Cage  Original International Harvester Corp. Final Part prints

4. Part #One: Exhaust Valve Cage

6.  Predicted Porosity

7. Part #One: Exhaust Valve Cage Manufacturing Plan PartExhaust Head Process Sub- Processe s LocationTools Core making Filling Core wash repairFoundryCore Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring ClosingFoundryPatterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Ou t SourceSand Blaster Grinders Paint Equip.

8. Part #One: Exhaust Valve Cage Metallurgy  Total Carbon =3.57%  Silicon=3.37%  Cu =?  Cr=.02%  Mo=.01%  P=.89% Desired Brinell Hardness HB=170- 200 Actual HB= 321

9. Part #One: Exhaust Valve Cage Grey Iron 80% type A graphite 20% type D&E

10. Part #One: Exhaust Valve Cage Molding

13. Part #One: Exhaust Valve Cage Pouring

15. Part #One: Exhaust Valve Cage Shake Out

16. Part #One: Exhaust Valve Cage Cleaned Parts

17. Part #One: Exhaust Valve Cage Casting Defects Gas defect only ( Blow) Gas defect only ( Blow)

18. Part #Two: Intake/Exhaust Manifold

19. Manufacturing Plan PartIntake/Exhaust Manifold Process Sub- Processes LocationTools Core making Filling Assembly Core wash repairFoundry Core Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring ClosingFoundry Patterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Out Source Sand Blaster Grinders Paint Equip.

20. Part #Two: Intake/Exhaust Manifold  Metallurgy  C=3.66%  Si =1.6%  Ni =0.9%  Cr=0.85%  Mo=0.65%  Cu =0.35%

21. Part #Two: Intake/Exhaust Manifold  Original Manifold  Manifold Pattern  Follow Board

22. Part #Two: Intake/Exhaust Manifold  Exhaust Core Boxes ( under construction)

23. Part #Two: Intake/Exhaust Manifold  Intake Core blank

24. Part #Two: Intake/Exhaust Manifold  Pin Core Box

25. Inspection Process  Solid walls  Inclusions  Surface defects (rat tails, buckles, burn on)  Pin holes  Cold laps  Inspection tools  Visual  Pressure test  Ultrasonic imaging

26. Budget

27. Schedule