Oct. 21, 2024
The valve cage regulates and helps control the flow of fluid through a valve. When supplied as a static sand casting, defects in the valve cage were often not discovered until much machining had been completed. The results were high scrap rates and cost. Working with the customer, MetalTek engineers converted the static sand casting to a centrifugal casting, incorporating the sand core technology into the design of the existing part. The homogeneous quality of a centrifugal casting reduced hidden defects. The rough casting was designed so that the last machining pass on the I.D. of the part opened the &#;windows&#;, minimizing the number of interrupted machining cuts. This further drove down scrap, which has been reduced by 98%.
Cencho contains other products and information you need, so please check it out.
Naval supply replenishment vessels transfer equipment and supplies to military ships in service, while allowing for the relative motion of the ships. They employ high horsepower continuous slip air clutches to control the tension of connecting cables between the ships to allow for motion of the seas and relative movement of the vessels. The drums became unreliable and subject to significant wear when the change to non-asbestos brake material was implemented. MetalTek pioneered the development of a Metal Matrix Composite (MMC) centrifugally cast material for use in the friction drums. The MMC material used in the drum application virtually eliminated corrosion and drum wear and reduced hourly operating cost by 90%.
Fabrications require extensive blacksmithing, welding, and polishing to produce a part that meets stringent USDA surface finish and specified design requirements. Even when those requirements can be achieved in a fabrication, the final product can often vary lot-to-lot, making interchangeability and consistent performance an issue. MetalTek&#;s Wisconsin Investcast Division successfully converted a complicated fabrication into a single large investment casting. This 280 lb./127kg stainless steel casting features nine spiraling flutes that contour along its entire length and contains as-cast surfaces that satisfy USDA requirements. As a result, the customer has enjoyed the benefits of significant labor savings, manufacturing capacity, consistency of production parts, and increased process throughout.
Certain industrial mixers and kneaders, especially those that process highly viscous materials, employ &#;Sigma Blades&#; to get the desired blending of the material. Manufacture of the blades presents challenges including alloy selection for corrosion resistance, casting, heat treat, and machining of such a large part&#;while retaining its shape. Working with the customer, MetalTek&#;s Carondelet Division developed a special alloy that did not require water quench to achieve desired corrosion properties&#;avoiding a significant opportunity for product distortion. Other fixtures were developed which simulated the machining envelope to ensure that the cast product could be machined to the desired shape. The customer realized a 150% increase in machine pass rates, and a 50% reduction in machining cost.
In the food processing industry, production of ground meat is one of the most demanding applications. Meat is forced through a network of small holes in a cylinder by a rotating Archimedes screw. Pressure on the cylinder wall is considerable, and the spaces between the holes are very thin. Forgings used in this application fail prematurely &#; cracks occur and tend to propagate due to the unidirectional grain structure in a forging. Centrifugal castings have replaced forgings in this application because the grain structure of a centrifugal casting is multi-directional. It is highly resistant to both crack initiation and propagation. Changing to a centrifugal casting in this application saved the customer money both in purchase cost and increased life of the product in service.
The ball valve manufacturer came to MetalTek because they were facing a common dilemma. Needing a ball in a specialty alloy offered only unattractive alternatives. Because of the material, purchasing a mill run to produce a forged ball was cost prohibitive. Machining a spherical component from a cylinder is a difficult choice, and there are static casting challenges when producing a sphere because of heavy wall sections and varying wall thickness. Fortunately, MetalTek offered the most logical of solutions. With ball tooling already available for sizes ranging from 2&#; through 38&#;, there was no tooling lead time or cost. Being a master melter, MetalTek was able to produce any quantity the customer needed in the alloy they specified.
Vortex flow meters provide an effective alternative to turbine flow meters in steam, oil, and gas applications. While extremely reliable, the proper placing of internal mechanisms is essential for the accurate measuring of fluids through the meter. There can also be a variety of sizes and bolt patterns of mating parts which attach to meter bodies. MetalTek&#;s Wisconsin Investcast Division brings a unique ability to integrally cast internal shutter components. MetalTek has also devised a common tooling scheme that allows a broad range of flange sizes and bolt hole patterns to be produced from a single tool. These capabilities help produce parts that perform in the field, add versatility, and minimize tooling investment.
Using the investment casting process is proven to help businesses save money, especially those who are looking for repeat and bulk orders. It&#;s no secret that investment casting is one of the most popular metal-forming techniques for manufacturers. Investment casting can be used in a multitude of industries including automotive, aerospace, military, medical, and various other industries. Of course, there are an array of benefits when it comes to investment casting and saving money is well up there with one of the most favourable benefits which allows businesses to reduce costs and increase revenue and profit margins.
In this blog post we will outline exactly how investment casting can help you save money.
One of the main ways that investment casting can save you money is due to its repeatability. There is no compromise in quality from casting to casting and the process provides an extremely reliable technique that allows for low-cost repeat runs.
Here at Precision Investment Castings, we aim to be as environmentally responsible as we can. One of the key ways that we can do this is to reduce waste throughout the investment casting process. Our investment castings are normally created to near net shape, therefore playing an impact in the overall cost of waste.
If you want to learn more, please visit our website stainless steel investment casting parts.
Featured content:Another notable reason that investment casting saves you money is due to the fact that low-tooling costs are involved. Compared to alternate casting methods, such as pressure die casting and gravity-die casting, investment casting is by far the more cost-effective option whilst also providing a very reliable technique and low-cost repeat runs.
Rapid prototyping is used 100% of the time with investment casting. Rapid prototyping allows engineers and designers the opportunity to approve the final prototype and/or adjust and make final changes before investment casting goes ahead. This helps you save money as you won&#;t be wasting money on faulty versions of parts of applications that don&#;t serve the desired purpose of function.
When you use the investment casting process to produce your specific parts and assemblies, you are guaranteed exceptional surface finishes simply due to the nature of the process. This helps to save you money because it reduces additional work and secondary machinery that otherwise would be required in order to achieve the same exceptional surface finish. Unlike alternative casting methods, such as forging and sand casting, investment casting will help to reduce overall costs and lead times due to this outstanding benefit.
Investment castings also helps save you money due to the guarantee of regular inspections that take place during the production stages. Regular inspections help us to prevent potential faults thereby reducing waste and having to do it all again. Our inspections are carried out by time served engineers who can quickly identify and rectify any future problems and ensure the integrity of our production runs without compromise.
With over 70+ years of experience in a wide range of industries, Precision Investment Castings are able to work with customers from a wide range of industries to develop the optimum product for the optimum price.
We can deliver in a wide range of materials including Aluminium, Carbon Steel, Stainless Steel, Bronze and Zinc.
Our services are backed by rigorous processes, testing and accreditations from the world leading quality organisations such as BSI and NADCAP.
Ready to get started? If so, please get in touch with us today to discuss your investment casting requirements by calling us today on 925 or use our online contact form and we&#;ll get back to you at our earliest convenience.
The company is the world’s best stainless steel lost wax cast supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
If you are interested in sending in a Guest Blogger Submission,welcome to write for us!
All Comments ( 0 )