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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!

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

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

Types of Investment Casting 

Though investment casting, also known as lost wax casting, has been around for thousands of years, there have been improvements to the method. The modifications are intended to improve the pattern development procedure and address the use of wax. Evaporative pattern casting is the general term for lost wax casting because the material used to produce the pattern is removed or evaporates.

Workers use the investment casting method

What Are the Different Kinds?

Casting in Foam

Engineers can use it to produce three-dimensional renditions of their conceptualizations. It is a manufacturing process used to make decorative, elaborate, and intricate metal shapes, arrangements, and designs.

Investment Casting in Water Glass

Instead of ethyl silicate, the water glass is employed as the shell’s binding agent. The technique, which dates back to the 1950s, has a material cost and manufacturing cycle advantages. It has a simpler technique, operation, and parameters that may be accomplished by ordinary personnel, resulting in increased production and efficiency.

Casting with Direct Investment

The first approach involves carving the pattern by hand or machine to generate a one-up version that is then treated using the lost wax method. This method is used to make a prototype, produce small batches of final products, or determine dimensions.

Sand Casting

Sand casting is used to make huge pieces by pouring molten metal into a mold hole that has been formed out of natural or synthetic sand. The cavity is constructed by using a pattern, which is usually made of wood or metal and is the same shape and size as the actual item. The cavity is somewhat larger as a result of the pattern being slightly oversize, which compensates for the contraction of molten metal during cooling.

investment casting manufacturing process

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Ferralloy, Inc. is a multinational corporation that provides competitively priced items made in North America and Asia to a global market. Schedule an appointment with us! We are available to answer any queries you may have.

Procedure of Investment Casting

Investment castings are one of the most common metal casting techniques today. Equipment and methodological advancements have kept up with demand throughout the years. The wax is melted out of the mold by heating it in an oven, leaving a ceramic shell mold for casting. 

investment-casting

 What Is the Mechanism?

 Construction of a Metal Die

The master die’s size must be carefully determined, taking into account the wax pattern’s predicted shrinkage, the ceramic material invested over the wax pattern’s expected shrinkage, and the metal casting’s expected shrinkage. 

 Production of Wax Patterns

The mold or die is inserted with hot wax and allowed to set. Any internal characteristics may necessitate the use of cores. The wax pattern is an exact reproduction of the part that will be manufactured.  

 Making a Mold

 The thickness of the ceramic shell is determined by the size and weight of the item being cast, as well as the metal pouring temperature. The solidified ceramic mold is flipped over and baked in an oven until the wax melts and drains away. As a result, a hollow ceramic shell is created. 

 Casting

 Liquid metal pours into the pouring cup, via the central gating system, and into each mold cavity on the tree while the molten metal is still hot. The metal flows freely through thin, precise areas thanks to the pre-heated mold. The mold and casting will cool and shrink together, resulting in a casting with increased dimensional accuracy. 

 Cooling

The metal cools and solidifies after it is placed into the mold. The length of time it takes for a mold to solidify depends on the material used and the thickness of the casting. 

 Shakeout

The ceramic molds break down and the casting can be removed once it has solidified. Manual or water jets are commonly used to break up the ceramic mold. Individual castings are detached from their gating system tree after being removed by human impact, sawing, cutting, burning, or liquid nitrogen cold breaking. 

Finishing

To smooth the part at the gates and remove defects, finishing processes such as grinding or sandblasting are typically used. Heat treatment may be used to harden the final product, depending on the metal from which the casting was made. 

metal-hardening

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Ferralloy Inc. is proud to offer some of the best-forged components in the market. Contact us or request a quote right now. 

What Is Sand Casting and Why Is It Used?

Sand casting is a method used for casting metal by pouring molten metal into a mold made from condensed sand. It has been used for hundreds of years and remains to be one of the most reliable and versatile methods of creating different castings to this day. While the main process has not changed over time, there are new advances to the method that have been developed throughout the years.

Removing formed metal from castings

Reasons to Use Sand Castings

Flexible Mold

The mold boxes made up of sand casting are extremely reliable and easy to make.  The sand mold can hold the metal’s shape as the metal cools down to reveal the desired cast design. The use of sand casting allows you to create highly complex shapes in almost any size and form from nearly every type of engineering alloy.   

Cost-Effective and Relatively Cheap

One reason why most metal castings around the world are manufactured using sand casting is that it is relatively cheap and cost-effective. Sand casting is one of the few available processes for metals that can be recycled because of its reusability. Its ability to mold sand to be reused is a great asset in manufacturing operations.  

Strong and Resilient

Sand casting molds provide the best outcome possible because it can withstand the high temperatures of liquid metal it holds when creating designs. It can also manage thermal contraction, metal flow, and gas venting to prevent defects and impurities during the process. By using high-quality sand in creating the mold, your project will not melt, burn, or crack as molten metal is poured into it.

Preparing sand castings for forging

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We have invested a lot in both material and technical skills to deliver the best components you can trust. Ferralloy Inc. will provide you with the finest materials to ensure that your costs are kept to a minimum while quality is maintained. Please contact us for a quote today!

Steel Castings vs. Cast Irons: Which Is Better?

Both cast iron and cast steel are ferrous materials that are primarily made up of iron and carbon. Both are excellent in investment casting in terms of qualities and are hence employed in various applications. They have excellent mechanical attributes, which will make it quite challenging to choose between the two. In this article, we’ll look at the fundamental distinctions between cast iron and cast steel.

investment casting process

Differences Between Steel Casting and Cast Iron

Steel Castings

  • In terms of impact loads, steel casting is superior.
  • Steel casting is more expensive than cast iron.
  • When compared to cast iron, cast steel has reduced flowability and shrinkage.
  • Steel casting outperforms cast iron in terms of vibration damping.
  • Steel castings have a higher melting point.
  • Steel castings have a significant quantity of other alloying elements.
  • The machinability and weldability of steel castings are both excellent.

Cast Iron

  • In terms of corrosion resistance and mechanical wear resistance, cast iron is superior.
  • Because of its excellent flowability and low shrinkage, cast iron is easy to operate in addition to that.
  • Noise dampening qualities of cast iron are excellent.
  • Cast iron is cheaper than steel castings.
  • Iron and carbon are the two most essential elements in cast iron. Other components may be present in trace amounts.
  • When compared to cast steel, machinability and weldability are inferior.
  • The melting point is lower than steel castings.

end result of the investment casting process

Want to Learn More About Investment Casting?

When you’re having trouble deciding between the two, speaking with an expert can help you make the right decision. Don’t hesitate to get in touch with Ferralloy for a quote or to learn more about how our casting service might help you with your project.

What Industries Can Benefit from Investment Casting?

When it comes to obtaining the parts you need for a product, there are a variety of manufacturing techniques available. However, it’s vital to understand which ones give the most pleasing results at the best prices with so many options. Investment casting is a process that has been used for centuries, and it is used in a variety of industries. Let’s take a look at how, why, and what the advantages are.

castings investment manufacturing process

Industries That Can Benefit from Investment Casting

What Are the Advantages of Investment Castings?

Oil and gas, aerospace, and military and defense sectors all demand dependable, high-quality parts that can satisfy particular criteria and survive the harshest conditions.

The aerospace industry, in particular, demands precision investment castings for interior and external aircraft components, ranging from sensors to hydraulic fluid systems.

Another area that benefits from investment casting is the automobile industry, owing to the technique’s design flexibility and capacity to make lightweight parts.

Investment casting is also essential in the oil and gas industry. Companies require components that can withstand the most extreme circumstances. As a result, heat and corrosion resistance in castings is critical.

Advantages of Investment Casting

As previously said, investment casting may be pretty beneficial to a variety of businesses. The following are some of the most well-known reasons for the process’s popularity in various industries:

Diverse Set of Applications

Investment casting is perfect for producing a wide range of components, from giant turbine blades to small, delicate engine parts, in various conditions and applications.

Flexibility in Design

With investment casting, you may choose from a variety of materials, sizes, and configurations. This method provides a wide range of design possibilities and the production of sophisticated, delicate pieces that can be cast to a near-net form.

Machining Time is Reduced

Investment casting is beneficial in industries where speed is of the essence. Further machining and adjustments are not required to bring the cast up to the clients’ standards. Not only are you saving money, but you’re also reducing the amount of time it takes to do the task.

worker pours hot metal during castings investment process

Want to Learn More About the Uses and Applications of Castings Investment?

A conversation with an expert can aid in making the best selection. Please get in touch with Ferralloy to learn more about this procedure or obtain a quote to learn more about how our casting service may meet your project’s needs.

How to Choose a Reputable Investment Casting Supplier? 

It’s critical to work with a reputable supplier when you require investment castings. So, how do you go about finding a dependable investment casting company?

Metal casting suppliers should not be selected in the same way as bolts, industrial equipment, or office supplies. While some may see metal castings as a commodity, they are far from it, and choosing the correct provider for a particular application necessitates considerable thought.

Workers in the middle of an investment castings process

Factors to Consider for a Reliable Investment Casting Provider

Experience

A steel casting company with a lot of expertise is relatively standard, but the most crucial thing to evaluate is whether or not they have experience in your industry.

steel distribution factory that understands where your products will be utilized and several other factors may also plan for and anticipate potential challenges ahead of time.

Quality and Qualifications

When deciding which steel casting company to choose, quality should be a top priority.

Another important consideration when choosing the finest steel casting factory is to ensure that your potential supplier has all of the necessary qualifications to attest to the excellent quality of the goods provided.

Capabilities in Machining

Clients are increasingly looking for casting companies with machining skills. If faults are identified during machining, this can help avert a conflict. If a third party is machining, accusations over who is to blame may ensue.

If a casting provider discovers a problem during machining, the issue is addressed sooner, and there is no debate over who is to blame. Because the foundry “owns it,” processing, transporting, and managing or replacing it takes less time.

a worker supervises the investment castings process

Want to Know More About Investment Castings?

The process of choosing the right supplier for your unique application necessitates significant thought. Determine what is most essential by conducting an internal audit of your company’s requirements and wants.

Ferralloy Inc. has invested in both material and technological skills to deliver components you can trust. We will supply you with the finest procedure choice to guarantee that your expenditures are kept to a minimum while quality is maintained. Please get in touch with us for a quote right away!

Cast Iron vs. Cast Steel: The Advantages and Disadvantages

Castings investment is one of the most popular methods for producing long-lasting and high-quality components. Because casting allows for a high level of detail, no extra manufacturing or assembly is required. While a variety of materials can be cast, steel and iron are the most used due to their outstanding mechanical qualities in a wide range of applications.

Castings Investment components

Differences Between Cast Iron and Cast Steel

Castability

Cast iron is a reasonably simple material to work with because it pours smoothly and does not shrink nearly as much as steel. Cast iron is a great metal for architectural or ornate ironwork structures such as fencing and street furniture because of its flowability. 

Resistance to Corrosion

When it comes to corrosion resistance, iron is superior to steel. That doesn’t rule out the possibility of corrosion in either case. Both metals will oxidize in the presence of moisture if left unprotected. They will eventually decay totally. The coating is advised for both steel and iron castings to prevent this. 

Cost

Because of the lower material prices, energy, and labor required to manufacture a final product, cast iron is frequently less expensive than cast steel. While raw steel is more expensive, prefabricated steel is also available. Sheets, rods, bars, tubes, and beams are among them.

Advantage and Disadvantage of Cast Steel

It is known that the design flexibility of cast steel is its key feature. The designer of the casting has the greatest creative freedom. Complex forms and hollow cross-section pieces are now possible. Cast steel, on the other hand, has poor shake-suction, wear resistance, and mobility. When compared to cast iron, the casting performance is poor. In addition, the costs are higher than with regular cast iron.

The Advantage and Disadvantage of Cast Iron 

Cast iron provides a number of advantages, including high wear resistance, machinability, and low notch sensitivity, to name a few. Its tensile strength and elongation, on the other hand, are extremely low. As a result, it can only make a restricted number of metal items that aren’t physically demanding.

Steel and iron castings both have advantages and disadvantages. Depending on the application and physical features, either should be employed.

Castings Investment components

Want to Know More About Castings Investment?

Ferralloy has invested in both material and technical skills in order to deliver components you can trust. Ferralloy Inc. will supply you with the finest process choice to ensure that your costs are kept to a minimum while quality is maintained. Please contact us for a quote today!