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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!

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

Want to Know More About Sand Castings?

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!

What Are the Advantages of Machine Castings? 

Machined castings are required if you want unique and seamless metal casting parts. As soon as they leave the mold at the factory, castings aren’t always ideal. Machining enables us to customize your casting to fit your specific requirements. Whatever machining process you want for your project, we keep it simple.     

Continue reading to discover more about machining and whether machined castings are suitable for your next project!  

  machined castings batch

How Exactly Is Machining Done?      

Three Primary Tools of Machining    

Machining is divided into the following sorts of machining tools, which are described in detail:     

Turning     

Turning is a lathe operation that involves removing metal from a workpiece outside its diameter with a cutting tool. This process is carried out on a lathe, which is a machine that allows the workpiece to be adjusted while the tool remains fixed and rotates the workpiece.   

Lathes are intended explicitly for turning operations and aid in the most exact cutting of metal. The workpiece is inserted into the chuck, and the machine spins the fixed tool to remove the undesired bits.     

Drilling     

Drilling is a method of making holes in metal using circular cylinders. This task is completed with a twist drill. The drilling procedure removes 75 percent of the metal cutting material.   

The drill is inserted into the workpiece and makes a hole the same diameter as the instrument used to cut the whole. The pointed end of a drill allows it to carve a hole in the workpiece readily.    

Milling     

Milling is one of the most basic machining procedures. Because the degree of freedom is excellent, this manufacturing technique is less precise than turning procedures. Milling is used to create objects that are not axially symmetric. For this, you’ll need a milling machine, as well as a fixture, cutter, and, of course, the workpiece.     

The workpiece, in this case, is a pre-shaped material that requires milling. It’s clamped to the fixture and ready to be milled. The workpiece is passed through the cutter, which eliminates the undesired metal.    

zirconium pipe fittings machined castings

How Do I Get Machined Castings?     

Machined castings might be challenging to work with. As a result, finding a company that knows both the casting and machining processes is critical.     

We can provide you with machined castings for your next project. Ferralloy Inc. can offer you high-quality as-cast or completely machined components that are both affordable and on schedule. Contact our metalworking specialists now for more information or a quotation on your machined castings! 

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!

When Should Investment Casting Be Used?

Investment casting is very popular in manufacturing when it comes to producing components with high accuracy, repeatability, and cast integrity. The process can be used to make parts for a wide range of industries and sectors, including oil and gas, automotive, aerospace, defense, and general industry. 

Workers are pouring gold into the mold stock for investment

When and Why Should I Use Investment Castings?

When High Precision Parts are Required

Investment casting, also known as precision casting, is the best option if you need a high level of precision. This process produces parts with excellent dimensional accuracy and complex shapes, and we can easily add details such as holes, lettering, threads, and serrations to meet the needs of our customers. 

When Medium To High-Volume Orders Are Required

If you need the same part over and over, investment casting is a great option. Because there is virtually no tool wear, this process provides consistency and repeatability. Furthermore, it is frequently the method of choice for projects requiring a medium to high volume of orders, as it saves both time and labor costs by eliminating the need for manual labor. 

When a Wide Range of Sizes Is Required

When it comes to the parts and components that are used, different industries will have different requirements. You can get the right part in the right size with investment casting. 

When a Low Overall Cost Is Required

Because investment casting produces superior dimensionality and precision, it is more expensive than die casting. However, the final costs make it more than worthwhile.  

The process can achieve the desired level of complexity in your parts and components without wasting material, and most investment castings will only require minor machining, which will save you time and money. 

Metal pouring process for investment casting

Want To Know More About Investment Casting?

We at Ferralloy have invested in material and technical expertise to provide components you can truly count on. Here at Ferralloy Inc., we will provide you with the best process option to ensure you that your costs are minimized, and quality is never compromised. Contact us for a quote today! 

Advantages of Investment Castings

Investment castings provide limitless advantages. It is often used as a metal component for energy, gas and oil, food service, commercial, military, automotive, firearm, power generation, and aerospace industries. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Castings investment is even used by beverage equipment manufacturers and industries, as well as, international pressure relief valve manufacturers in the oil and gas industry.

castings investment

Advantages and Uses of Investment Castings

What Are the Advantages?

Investment casting is perfect for crafting complex and small geometric shapes that have delicate features with only a single mold. Since it is highly flexible, you can combine it with various wax patterns to make a single unique mold. It allows you to rearrange parts you could not make with a tool or machine. Hence, the results become a worthwhile substitute to wielding.

Smooth finishes and dimensional precision are some of the advantages of this casting process. The manufacturer forms a ceramic shell surrounding even patterns, eliminating any presence of a parting line. The reason for this is there’s only a single mold created. Therefore, this process can lead to a smooth finish and the post-process smoothing can produce better results.

Castings investment also provides excellent design capabilities, tight tolerances, and makes use of reusable materials. In this way, the project can achieve accurate results without having to spend more money. Thankfully, the process takes advantage of reusable materials.

How Are Investment Castings Used?

Investment casting is great for creating prototypes and small products. It has boundless applications across numerous industries, specifically in the industrial and automotive industries. How industries use this process today varies on the metals they need. Nonetheless, refractory metals that can withstand high temperatures work best. The most common metals used are titanium alloy, steel, and aluminum alloy.

castings investment

Get the Finest Investment Casting Product Today!

At Ferralloy Inc., we supply investment castings to quality-controlled companies and industries. If you’re interested in purchasing these castings, you can contact us through this link. Don’t hesitate to get in touch with us. Your business interest is what we prioritize!

How were Investment Castings Used in the Past?

Investment casting, otherwise known as a lost wax casting, is one of the oldest metal-forming processes that is still used as of this date. Approximately 5,000 years ago, investment castings started with a basic beeswax-formed pattern. Today, it involves highly complicated processes and technologies using refractory materials and specialized alloys.

what should i know about investment castings?

The History of Investment Castings

Original Use

The use of investment castings in ancient civilization was a bit different from the current method applied today. In the olden times, the craftsman designed the casting from beeswax by using basic tools such as shaving tools, melted wax, and other hot tools. To create the desired form, the craftsman will forge a pattern on the wax shape.

They will then fill the mold with a thin layer of melted wax. As soon as the wax mold is coated in ceramic, a perfect mold of the wax shape can be created. It will then be left to dry out before the craftsman can use it to forge a metal object. Such a process is generally used to create jewelry, decorative objects, and religious objects.

Modern Use

Investment casting is a complex metal-forming development that allows metal workers to create products with intricate and remarkable surfaces. The process starts by creating a mold and producing accurate patterns through the latest technological advancements. The good thing about the modern application of investment castings is that when the workers use wax to make patterns, it can still be reused.

The flexible patterns allow for easy reproduction and stress-free production of wax materials that underwent a series of coating and hardening. Once the materials are invested – jargon for poured – into the mold decorated with unique patterns, it will go through a lot of processes such as dewaxing, heating, pouring, removal, and cleaning.

what should i know about investment castings?

What Makes Investment Castings a Popular Metal-Forming Process?

If you want to know why investment casting survived throughout these decades and remains a widely used process, contact our staff at Ferralloy Inc. We can walk you through its history and help you realize why it’s an important metal-forming process.