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Machined Investment Casting for Global OEM

Project description:

At Ferralloy, Inc., we specialize in developing innovative solutions to some of the most difficult casting projects. In this example, we competed with three other foundries, from a field winnowed down from ten, for a contract to produce three different machined investment castings for a global OEM in the commercial equipment industry. The evaluation involved many levels of quality performance and a few of our competitors even alleged that the design specifications were impossible to achieve. Although we were not the lowest bidder, we won the contract based on our powerful engineering skills and our proven ability to uphold exceptionally close as-cast tolerances.

Machined Investment Casting for a Global OEM

One of our key strengths is our proficiency for overcoming challenges and engineering turnkey solutions for demanding applications. By tapping into our competencies across a range of engineering disciplines, we developed a strategy for vacuum casting each of the three components. We used our technical knowledge to create patterns and molds to reproduce complex shapes, prevailing over geometries that were complicated and prone to distortion. With our controlled pour, diligently monitored vacuum casting process, we consistently produced near-net-shape parts with excellent mechanical properties.

Cast from 304 stainless steel, the parts featured a polished and brushed finish. Quality assurance involved magnetic particle testing and x-ray inspection to ensure their mechanical integrity. For the past five years, we have been supplying these castings in quantities of 10,000 to 30,000 units annually. The quality of these stainless steel castings, combined with our ability to satisfy strict inventory replenishment requirements, earned us recognition as one of only a few Level 1 suppliers to this company.

If you are interested in learning more about this project or our vacuum casting and engineering capabilities, contact us today.

Project Name & Description

  • High Volume Production

Capabilities Applied Processes

  • Investment Casting (Vacuum)

Equipment Used to Manufacture Part

  • Vacuum Furnace & Pouring System, Lathe

Tightest Tolerances

  • ±.002″

Material Used

  • 304 Stainless Steel

Material Finish

  • Polished & Brushed

Industry for Use

  • Commercial Equipment

In Process Testing Inspection Performed

  • Magnetic Particle Testing & X-Ray

Volume

  • Item 1 – 10,000 Annually
    Item 2 & 3 – 30,000 Annually

Delivery/Turnaround Time

  • 14 Weeks

Standards Met

  • ISO9001: 2008