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Common Applications of Castings Investment

One of the most often used metal components nowadays is castings investment. Numerous advantages of these cast components make them a desirable solution for various enterprises and industries. For extremely complicated items manufactured from a variety of alloys, this process offers the utmost design flexibility.

Additionally, the casting investment procedure is rather straightforward, enabling high production rates and reliable dimensional precision. It’s understandable why they are chosen for so many various applications, given their advantages. What purpose does casting investment serve exactly? Discover some of the most typical applications in the following paragraphs!

rolled rings and castings investment

Important Thing to Know About Castings Investment

Where Is It Used?

It has a plethora of uses. However, the industries that employ these metal parts the most are aircraft, power generation, handgun, automotive, military, commercial, food service, gas and oil, and energy sectors.

For instance, the weapons industry uses cast components for precision elements like hammers, triggers, and receivers. Even producers of equipment for the beverage industry and producers of worldwide pressure relief valves for the oil and gas sector employ investment castings. It is reasonable to assume that investment cast parts and components may be the best metal choice for all of your projects, regardless of your industry, if your company can profit from their advantages.

castings investment in airplane

Where to Inquire About Castings Investment

At Ferralloy, Inc., we are the leading supplier of superior investment castings for every project need. Both high volume and low volume orders can be processed at our facilities without stress and inconvenience on your part.

Furthermore, we can maintain component inventory on blanket orders to meet delivery deadlines. We can tackle the problems of just about any project in any industry because of our knowledge, expertise, and experience. Contact our professionals at Ferralloy, Inc. to place your order!

Can You Cast Metal at Home?

Making a pattern and a mold, then pouring molten metal into the mold is the fundamental step in the casting process. After that, the manufacturer will remove the solid metal castings and complete your sculpture. This method is adaptable to diverse metal casting forms, sizes, kinds, and other factors.

end result of castings

Learning the Casting of Metal

Unlimited Options

Before you delve into the steps on how to cast metal at home, it’s best that you know the basics of casting a metal. The options in metal casting are unlimited, whether you wish to cast a simple ring or a complicated piece of metal for a vehicle engine. Your idea of the finished product will determine the kind of metal casting you opt to pursue.

If making jewelry is something you’re interested in, you should deal with precious metals such as platinum, silver, and gold. Your casting options may include anything from cast-iron skillet to modest aluminum tiles if more industrial tasks interest you.

Know the Purpose of Metal Casting

Metal casting is a very adaptable process, even though the majority of castings made worldwide are for transportation and heavy machinery. The following items most likely contain metal casting components:

  • Artistic and sculptural objects
  • Machining tools
  • Transportation: shipping, railways, aerospace, and automobile
  • Defense equipment, tools, and weapons
  • Farming equipment
  • Electrical components
  • Construction equipment
  • Household appliances

Not Advisable When You Have No Experience

Generally, you can set up your own home casting station and foundry, but safety should be the top priority. Once your objectives are clear, you can look at your learning possibilities. In order to meet safety standards, try to get access to a studio and learn metal casting from a qualified instructor. It is also advisable to start with a qualified and experienced expert. Below are some tips you have to consider:

  • Wear long sleeves, natural fiber garments, long pants, insulated gloves, safety goggles, and other protective equipment wherever possible.
  • Work in a well-ventilated area to reduce your chance of exposure to hazardous gases.
  • You should also keep the passageway between the furnace and the mold clear.
  • Make sure you have a chemical fire extinguisher close by.

combined metals for easy castings

Learn More About Castings

At Ferralloy Inc., we want the best for our customers. If you have any questions, let us know!

Machining vs. Casting

You need to understand the significance of the casting process as a part of metalworking before you can properly appreciate the beauty of machined castings. This process enables the production of a wide range of complicated metal components in a wide range of metals for a variety of industries.

Although castings can be utilized as-is when they come out of the mold, in most circumstances, they need to be machined to enhance the quality of each part.

metal parts produced through machined castings process

Difference Between Machining and Casting

How Does Casting Work?

The heated liquid metal is poured into a mold with a cavity or a hollow cutout of the desired finishing shape during the casting process. The molten metal is taken from its mold once it has cooled and solidified, revealing the casting form.

These castings go through stringent quality tests, which frequently include a video borescope, to guarantee a high-quality finished product. The manufacturer can use this tool to check for FOD, residue, and other flaws.

What Is Machining and How Does It Work?

Machining is the process of removing particular materials in order to change the appearance and shape of a metal product or casting. Cutting with single-point or multipoint cutting tools, grinding, and non-traditional machining processes that use electrical, chemical, and other sources of energy are all examples of machining processes.

Aside from the ability to seal threaded holes and other surfaces, machining also allows you to make fine and detailed metal works that would be hard to achieve with only casting processes.

end product of machined castings

Are You Looking for Machined Castings?

If your next project necessitates the use of machined castings, you’ll need to source them from a company that specializes in both casting and machining. Ferralloy, Inc. is the world’s leading provider of designed products and services that provide entire supply chain management to a broad range of metalworking customers. Get in touch with us right away!

Is Steel Good for Casting?

Steel castings are incredibly strong and durable, making them ideal for a wide range of applications. They are also resistant to both heat and corrosion, meaning that they can withstand high temperatures and harsh conditions.  

In addition, steel is relatively easy to cast, which means it can be used to create products with intricate designs. It is also castable at lower temperatures than other metals, making it ideal for use in extreme situations.  

Full frame background of small cold gray steel castings

Comparison Between Iron Casting and Steel Casting

Iron Casting

This process is also popular because iron is plentiful and the castings are strong and durable. Iron casting is also an ancient art that has been used for thousands of years. Today, it is still used to create a variety of objects, from cookware to sculpture. The iron castings produced today are of a high quality and can last for centuries.  

Steel Casting

Aside from the advantages mentioned above, there are some disadvantages to using steel for casting. Steel is significantly heavier than other metals, making it difficult to transport. It is also more expensive than other metals, making it a less cost-effective option in some situations. However, considering all the factors, steel is a versatile and durable metal that has many advantages and a few disadvantages for casting applications. 

The Verdict

Steel castings are widely used in a variety of industries for their strength, durability, and precision. They are made by pouring molten steel into a mold, where it cools and hardens into the desired shape. Iron castings are also used in many applications, but they are not as strong or durable as steel castings.  

In addition, iron is more susceptible to corrosion than steel, making it a less desirable choice for some applications. However, iron castings are typically less expensive than steel castings, making them a good option for budget-conscious consumers. 

plastic castings vs steel castings

Eager to Know More About Steel Castings?

If you’re planning to dive into the metal casting industry, you can contact our professionals at Ferralloy Inc. They will be glad to assist you! 

Oil and Gas Investment Casting

Oil and gas investment casting is used in the transportation, manufacturing, and energy industries for refining, storing, and transferring natural gas and petroleum products. Components applied in the oil and gas industry must be long-lasting and composed of materials that are resistant to chemical and environmental deterioration.  

Cobalt-based alloys, stainless steel, and other casting materials are used to produce high-quality components with wear resistance, corrosion resistance, and high strength for demanding applications. 

Metallurgical plant and hot liquid iron investment casting

What to Know About Oil and Gas Investment Casting

Oil and Gas Industry

Ferralloy Inc. is a certified investment casting foundry with several years of expertise. Our investment casting experts can assist you with everything from design issues to alloy selection for your specific operating environment.  

It is highly recommended that you get the services of a company that specializes in casting parts with intricate cored passageways and thin walls. Likewise, finished products should also maintain tight tolerances to satisfy the design requirements.  

National Aerospace and Defense Contractors Accreditation Program (NADCAP) accredited heat treating and welding, as well as non-destructive testing to assure casting integrity, are available for oil and gas castings. 

Casting Components for the Oil and Gas Industry

There are several companies that manufacture a variety of products for this industry, including the following: 

  • Drill tiles
  • Feed fingers 
  • Ramps 
  • Wear insects 
  • Burner management 
  • Control bodies & covers 
  • Valve bodies 
  • Field machinery components 
  • Process control instruments 
  • Pump impellers  
  • Down hole drilling components 
  • Valve components 
  • Filter screens 

Primarily, the materials used in investment casting are tool steel, cobalt, bronze, brass, carbon steel, aluminum, and stainless steel.  

Roll of hot metal on the conveyor belt investment casting

Request a Quote for Investment Castings in the Oil and Gas Industry

At Ferralloy Inc., we provide oil and gas investment casting that meets or surpasses client and industry criteria by employing high-quality materials and meticulous methods. To discuss your project, schedule an appointment with us. 

When to Use Investment Casting

Lost wax investment casting, commonly known as investment castings, produces a variety of metal components with exceptional as-cast surface quality and precise detail. These are shaped into interior or exterior features, thin walls, and internal passageways to achieve a near-net shape. Compared to conventional metal casting methods, these properties generally result in significant material, labor, and machining cost savings.

quality valves as a result of investment castings

Uses of Investment Casting

Shape

Experts use investment castings when there are external shaping and stringent tolerances. Likewise, it is also used when the parts are shaped or non-symmetrical with an exquisite detail.

Tolerance impacts product design, manufacturing, and quality control, making them crucial to the ultimate product’s success. As a result, setting tolerances and the amount of allowable variation in cut components is an essential aspect of the quality cost.

The goal is to balance lowering costs excessively and imposing too many regulations. Inspections, specialized equipment, higher scrap, and lower yields can all be increased by a tighter tolerance than is required.

Sand Casting

Investment casting is also resorted to when the wall thickness is too thin for sand casting. Sand casting molds are made by compacting sand around a pattern or model of the final product. It is usually mixed with clay as a bonding agent and saturated with water.

The design is taken from the mold once it has been torn apart. The mold’s two pieces are reassembled, and the void is filled with molten metal. It is then opened, the sand is removed, and the item is removed once the metal has cooled sufficiently.

from ladle pouring red hot steel to investment castings

Want to Know More About Investment Castings?

At Ferralloy, we’re always ready to help our customers and answer questions. Contact our experts today to know more!

Traits of a Reputable Seamless Rolled Rings Supplier

As a manufacturer of heavy-duty machinery or equipment, finding a reliable source for seamless rolled rings is crucial. In far too many products used in the energy, defense, and aerospace industries, these rolled rings are a critical point of failure. They must be resilient, robust, and able to withstand extremes in weather, pressure, and temperature.

There are four factors to consider when choosing a partner for your seamless rolled rings:

  • On-time shipping or delivery
  • Comprehensive Testing
  • Certification
  • Proven History

worker checks seamless rolled rings

Questions You Need to Ask Before Choosing a Supplier

Is the Provider Going to Deliver on Schedule?

Your supply chain’s complicated relationships are vital to your company’s success. The supplier must recognize their significance in your business and consistently deliver on schedule.

Is the Source Well-Tested to Ensure Dependability?

The adherence of your supplier to strict quality standards and requirements is essential to guarantee authenticity and credibility. More so, it’s also important to oversee expenditures in cutting-edge machining technology and quality assurance and testing standards. Prior to delivery, every forged ring should be labeled for traceability and physically or dimensionally inspected.

Is the Supplier’s Track Record in Production at Par?

There are various sellers out there who just sell low-quality products. The majority of these businesses fail shortly because their products do not withstand the test of time.

When selecting a rolled ring supplier, aim for a company that has a reputable and extensive history of supplying high-quality, long-lasting forged ring products. Without it, you’re putting the quality of your goods as well as your industry reputation in peril.

workers talk about seamless rolled rings

Looking for a Reputable Seamless Rolled Rings Supplier?

Ferralloy Inc. is known as a leading supplier of high-quality ring forgings. Contact us today!

Die Casting vs Machining

Machining and die casting are two of the most used industrial procedures for producing metal products. Both procedures can potentially be combined to achieve the most significant result. However, there are some crucial aspects to consider when deciding between the two processes. It may be challenging to choose, but it’s always important to get this part of the job done with all things considered. Continue reading to learn when to utilize machining or die castings.

rolled rings that have undergone castings process

Difference Between Machining and Die Casting

Machining

Machining, especially when it involves Computer Numerical Control (CNC), simplifies the operation by sculpting the object out of metal using robotics. Its processes include straight turning, taper turning, form turning, contour turning, boring, drilling, and milling. Machining also uses exotic and precious metals such as:

  • Tantalum
  • Superalloys
  • Platinum
  • Palladium
  • Niobium
  • Monel
  • Molybdenum
  • Kovars
  • Iridium

Castings

Melting metal and inserting it into a steel mold is the process of die casting (the die). The metal is then cooled until it solidifies into the desired shape. The common materials used in forging are titanium, carbon steels, tantalum, superalloys, cobalt alloys, stainless steels, Rene, Inconel, Haynes, and alloy steels.

castings process

Maximize Your Returns with Castings

Both of these methods are commonly employed to make metal fittings and components for everyday goods, such as computers, vehicles, and aerospace parts. Industries in agriculture, architecture, electronics, dental, and medical fields can significantly benefit from forging and machining processes. To get cheaper treatment costs, you have to determine which is appropriate for your business.

It is prudent to exercise caution while making an early investment in a project, especially if your budget is limited. If you’re not sure which strategy is best for you, talk to our Ferralloy professionals about it.

Which One to Choose: CNC Machining or Die Casting?

Computer Numerical Control (CNC) machining is more costly than die casting, but this varies depending on the production volume and kind of parts. It is frequently used to make the die and/or to add more advanced functionality to a die-cast product. Here are some of the factors to consider when comparing the various procedures to boost castings investment.

cheaper rings because of castings Investment

Factors to Consider

Waste

Die casting leaves only a few scraps steel behind, making it more economical. When slicing away sections of a metal block, CNC machining can end up leaving a lot more waste. If you want to reduce waste but prefer CNC machining, you’ll need to set up a recycling system so that scrap metal may be reused.

Precision

Die casting can produce complex geometrical shapes with precision, but it can also produce surface defects such as flashes or burrs, which require machining to remove. CNC machining, especially for highly customized small parts, may produce final products with a high level of tolerance and precision. Die casting is still a fantastic alternative for making identical parts when the surface detail can be carved into the master mold.

Speed

Die casting is simpler, faster, and more reliable than CNC machining. Even if post-casting machining is needed, it will take much less time than machining a complicated object from a solid piece of steel. Die casting is more reliable for creating large quantities because of its faster production cycle. However, CNC machining might generate a shorter lead time when producing lower numbers if you have the digital model ready. When developing prototypes, it can also be quicker.

perfected ring production due to castings Investment

Learn About Castings Investment

CNC machining does not require high tooling costs if you simply create a small volume of items. On the other hand, die casting is the best choice for reliable quantity and quality in big volume production.

Contact Ferralloy today to know more about CNC machining, die casting, and castings investment!

Machined Castings in General

Machined castings are required if you want to make a metal cast product that is unique. As soon as the mold leaves the factory, the castings aren’t always perfect. We may modify your casting to match your specific requirements thanks to machining. We keep it simple no matter what type of machining you need for your project. To get it up to your specifications, we employ metal components, a tool, and a machine.

inspection of machined castings

Machined Castings as a Workaround

Milling

The component is securely secured to the machine table during milling. To create various characteristics on the casting’s face, the cutting tools, which use interchangeable carbide or ceramic inserts, move and spin at the correct speed across the workpiece. On a horizontal or vertical axis, this can be done.

Grinding of Surfaces

It’s used to make a flat surface that’s precise. With non-ferrous castings, the component is held in place by a magnetic plate or a holding fixture. A carborundum grinding wheel, which rotates at a high rate to achieve the desired finish, is used to grind the castings outside edges.

Drilling by Hand

It’s used to make holes in the component by drilling or tapping them. The placement of the holes is determined by custom drilling fixtures or cast dimples that are inserted during casting production.

Inspection

The final stage of the procedure is intended to ensure that the machining work is up to par with the specifications. During the machining process and after the casting is finished, automated equipment and probes are used to check the casting.

machined castings made of steel

How Do I Get Machined Castings?

Working with machinable castings may be tough. As a result, it’s vital to get your parts from a company that can both cast and machine them. If you’re looking for machined castings for your next project, we can help.

Ferralloy Inc., formed in 1978, is able to provide you with high-quality as-cast or fully machined parts at a reasonable cost and on-time delivery at a reasonable price. We are a company that is focused on improving processes and providing excellent customer service. Contact our metalworking professionals today for more information or a quote for your machined castings!