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What is Shock Resistance?

In product condition processes, shock resistance testing is used to assess the impact of sudden acceleration due to the collision, drop, and explosion. Companies focused on castings investment and forging perform this test to develop products that can withstand harsh military, transportation, and industrial environments.

Castings Investment

What You Need to Know About Shock Resistance Testing

Simulate Real-World Use

Although shock resistance testing is sometimes compared to vibration testing, the former involves a more complicated and extreme process. The procedures are designed to use a specific type of force to recreate real-world use. Producers and manufacturers use an accelerometer to gauge the force and speed. Through this, the materials will be exposed to loads of pressure and impact.

After which, they assess and classify the material for stress and damage. Because of these rigid procedures, manufacturers and producers are able to guarantee that the product can meet the demands of its work setting.

Accurate Results

A team of experts conducts shock resistance testing that complies with several military and industrial standards such as EN 60068, DEF STAN 00-35, MIL-STD-810, and RTCA DO-160. These engineer experts aim to support custom and complicated projects through the assistance of specification selection and protocol development processes. Since manufacturers and producers possess a global platform of experts and laboratories, getting accurate results on time is never an issue.

Other Tests

Aside from the shock resistance test, there are also other tests that manufacturers routinely perform to guarantee quality results. Some of the tests employed are impact testing, drop testing, shock and impulse testing, bump/shock testing, decaying sine wave testing, shock pulse testing, and operational crash safety.

Castings Investment

Tests Employed in Castings Investment

Are you interested in learning about the other tests used in castings investment and how they can benefit the material cast? Contact Ferralloy Inc., today so our experts can address your questions!

Why Go for Aluminum Castings Investment?

Aluminum is considered to be one of the best materials used in castings processes. It is often used in permanent mold casting, sand casting, die casting, and castings investment. This material is widely known for its excellent strength-to-weight ratio, making it an ideal metal component for numerous casting applications.

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Perks of Using Aluminum Castings Investment

Heat Treatment

When employing castings processes for this type of material, it’s best to use the extensive de-gassing procedure and resistance melting process. This guarantees that tight tolerances are maintained and excellent repeatability from the first material to the last. Likewise, the casting process allows for heat-treating that can be utilized to provide the product greater machinability, corrosion resistance, ductility, and strength.

Wide Applications

When it comes to casting aluminum, there are a lot of companies that benefit from this process. The numerous industries that utilize aluminum castings are those engaged in electronics, military, aerospace, food and dairy, and dental or medical equipment. Examples of aluminum-casted products are pistol frames, levers, medical devices, valves, and heat sinks.

Near-Net Shape

Another advantage of using aluminum is that the material provides better surface finishes, tight dimensional tolerances, and greater alloy flexibility. With this, the result can achieve the near-net shape that needs less machining and other processes that may increase the cost.

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Inquire About Aluminum Castings Investment

Ferralloy Inc. offers high-quality aluminum-casted products. We are a leading supplier of quality castings to major companies throughout the world. Our staff is equipped with extensive domestic and international expertise to cater to your needs.

If you’re planning to use aluminum castings in your company, request a quote today by contacting us through this link so we can provide you with as-cast or fully machined parts in many different ferrous and non-ferrous alloys!

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.

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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.

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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.

Do You Know About Lost-Wax Casting?

Lost-wax castings are commonly known as precision castings or investment castings. It is a procedure of designing and building an object with the use of a variety of metals. From simple to complex objects, lost-wax casting use metals like bronze, brass, silver, or gold to create an original pattern or model.

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The Lost-Wax Casting Process

A Little Bit of History

Investment castings are known to be the oldest metal-forming procedure that dates back in 4000 BC. Even though it is the oldest known technique, innovations and technique evolutions made it possible to offer exceptional metalwork. Likewise, it is extensively used to produce objects for art, dentistry, and jewelry. 

Making the Mold

The investment castings process starts with carving a mold out of wax. To get exceptional metalwork, you need to look for a casting industry that can handle your design’s size and complexity. The experts’ skill and the equipment used should be in line with what you want your finished product to be.

Upon making and casting the mold, it will be intensively polished to comply with the exact measurements and dimensions. It is then used to create another wax mold that will be heated and transformed to create a more flexible mold. 

Assembling the Wax Pattern

To guarantee product quality, investment castings use different methods such as coordinate measuring, ultrasonic, and dye penetrant. These methods will be used according to where the metal components will be used. Dye penetrant testing is a nondestructive method, and it includes cleaning the surface of a product, then applying a colored penetrant or dye. The wax pattern will primarily depend on which way will be used.

Finishing the Metalwork

The casted components are sandblasted, machined, ground, or files to attain the desired surface finish and final geometry. If necessary, the cast components are likewise heat-treated to improve the mechanical properties of the metalwork.

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Know More About Investment Castings

If you want to know more about the products designed through investment castings, contact our experts at Ferralloy Inc. today!

How the Investment Casting Process Works

To produce many specific metal components, the metal undergoes certain processes to achieve the shape and quality. For products like investment castings components, it needs to undergo a rigorous process called machining. This process is very complicated and crucial to the quality of the metalwork. You also need to remember that there are various tools and techniques within machining specific to the component and its purpose. 

Depending on what the investment casting component will ultimately be used for, the rigid and complex process it undergoes may still vary. To find out more about how the investment casting process works, below are the applications and types used. 

Machined Investment Casting Applications

Investment castings are essentially used in power generation and aerospace industries to produce a variety of components. The process in investment casting includes the operation of machining the metal after it has been manufactured. This is to have it made and delivered to the company’s exact specifications. In the power generation and aerospace industries, it is imperative to guarantee that any accurate measurement is achieved in machined investment casting. 

Types of Machining

The tools, techniques, and technology involved in machining vary between different tools used for cutting. There are times where machined investment casting needs a specific texture or an exact measurement. Likewise, in each case, an additional device is utilized. A few of the different machining operations types include turning, drilling, boring, reaming, and milling. 

A single edge cutting tool is used to eliminate excess material from a rotating component to produce a cylindrical shape when it comes to the turning process. As for the drilling process, a round hole is being created. A single bent tip is used to advance the precision of an already roughly made hole. 

The reaming process involves the removal of a small amount of excess metal from an already drilled hole. Lastly, milling is a rotating tool with several cutting edges utilized to create a straight surface.

Looking for Quality Investment Castings?

Ferralloy Inc. has the experience and authority to offer this service and product to you. As an industry leader, Ferralloy, Inc is equipped and experienced in delivering high-quality metal components at competitive prices. Contact our metal component manufacturing company today!

Tips When Looking for a Forging Manufacturer

Over the years, the forging industry has massively evolved. The use of different techniques and processes in forgings gave rise to various applications in construction, agriculture, automotive, machinery, and so much more. Below are the tips you may want to consider in looking for a forging supplier or manufacturer.

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Guide in Choosing a Forging Manufacturer or Supplier

Know Which Type You Want

Forgings have two most popular forms. These are open die forging and closed die forging. Although both originated in the fundamental forging process that involves beating a piece of metal until the desired shape, strength, and granular level is achieved, these two processes have differences.

Choosing a Company That Delivers On-Time

Did you know that your success as a company depends on the complex relationships that make up your supply chain? Be sure that your supplier supports your success and delivers on-time, all the time. A delay in the delivery will make things complicated and may even compromise your production.

Fact Check of the Company’s History and Reputation

Sellers and manufacturers aren’t hard to find. Some companies focus on low-cost and low-quality solutions. Hence, you can immediately spot them as their products fail to stand the test of time. 

Thus, it’s essential to look for a reputable supplier with a proven history of producing forgings that offer high quality and durability. Your reputation in the industry is at stake if you fail to choose companies that provide quality forgings.

Look for Any Certification

The supplier or manufacturer you chose to provide you with forgings must adhere to industry standards and specifications. In this way, produce durable and resilient forgings that can withstand extreme temperature, pressure, or adverse weather conditions.  

Certified suppliers and manufacturers maintain data-driven systems that are continuously audited. Aside from the fact that they quickly address quality issues by creating quality improvement plans, they also conduct subsequent reviews to monitor and evaluate these plans’ effectiveness.

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Get Quality Forgings at Ferralloy!

Having achieved ISO 9001 certification in both locations, we are a quality-driven organization committed to process improvement and customer satisfaction. Contact us today!

Precision of the Lost Wax Casting Process

A casting investment is often resorted to because it can produce metal components with near-net shape, thin walls, precise shape into external or internal features, exceptional surface finish, and can produce fine details.

This normally results in highly satisfactory customer cost savings in machining, labor, and materials. One of the processes often used to get an accurate casting is the lost wax casting. Read on to know more.

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How Precise is the Lost Wax Casting Investment Process?

What is the Lost Wax Process?

In lost wax casting investment, a specific and general wax pattern of the preferred finished part is produced and mounted onto a wax tree. This first process involves the use of the metal delivery system. The wax tree is interchangeably plunged into a ceramic substance and topped with a stucco material. After this, it is left to dry out, and the process is repeated until a thick shell is achieved.

Once the shell is achieved, it is then melted out, creating a cavity in the form of the preferred pattern. The molten metal is then poured in such an area until it is filled. After the molten metal solidifies, the thick shell is fragmented, and the gating material is detached. The remaining parts are the finished product.

What are the Characteristics of the Lost Wax Process?

The distinctive characteristics of the lost wax casting investment are accurate tolerances and low roughness values. Moreover, considerable autonomy exists in both material choice and product design.

Accurate castings are usually applied in areas where high-quality metal components are demanded. For example, finished products brought by the lost wax process are often used in areas with substantial temperature differences and hostile or aggressive environments. Additionally, because of high and specific demands, unique and rare alloys are commonly used for these castings.

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Specializing in Lost Wax Casting Investment

To get the most out of your purchase or investment, you must use the services of companies that specialize in the lost wax process. On the other hand, you can simply seek companies that will do the job of looking for specialized companies that produce high-quality and high precision metal finishes. At Ferralloy Inc., we guarantee that only the best products are provided and offered for you to choose from. Contact us today!

How Accurate is Investment Casting?

Investment casting is one of the first and most common types of metal components. The procedure to create these components involves pouring molten metal into a ceramic mold. The metal solidifies within the mold, and then the metal casting is broken out. Industries that focus on food equipment, railroad, heat treating, steel production and processing, coal mining, road construction, oil, aerospace, aircraft, and other countless industries discovered the benefits of this type of casting.

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Accuracy of Investment Casting

Near Net Shape

Investment casting is extremely accurate and near net shape. Since metal components are created by using the same wax pattern, this accuracy can be maintained from casting to casting. Additionally, this process uses stainless steel, aluminum alloy, titanium alloy, or superalloy to create and yield precise metal components that can withstand high and low temperatures.

Additionally, near net shape manufacturing is an ideal solution for those wanting to save money as much as possible. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any time for machining done, you can save on production costs.

Intricate Design

When using investment casting, engineers can design and create a lot to customize your product. Logos, product ID’s or numbers, letters, thru-holes, slots, blind holes, external and internal splines, gears, and thread profiles are just some of the intricacies that can be done.

Guarantees Product Quality

To ensure product quality, investment casting uses different methods such as coordinate measuring, ultrasonic, and dye penetrant. These methods will be used according to where the metal components will be used. Dye penetrant testing is a nondestructive method, and it includes cleaning the surface of a product, then applying a colored penetrant, or dye.

Ultrasonic testing is also nondestructive testing that works by sending high-frequency wavelengths through an object to detect cracks and other possible flaws. Lastly, coordinate measuring uses a probing system in the machine, and data collection allows for precision, which results in durability.

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Where to Look for Investment Casting

It is important to ensure that any exact measurements are achieved in machined investment casting. At Ferralloy Inc., we have the experience and authority to provide this service and product to you. Contact us today!

A Simple Guide to the Uses of Investment Casting

Investment casting is one of the most prevalent metal parts used by most industrial companies. These cast components embrace countless benefits that make them an alluring alternative to a wide range of businesses and industries. Investment casting provides the ultimate design flexibility for highly complex parts made from a large choice of alloys. Furthermore, the investment casting process is relatively simple, allowing high production rates and consistent dimensional accuracy to be achieved.

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Simple Facts Should Know About Investment Casting

What is Investment Casting?

Investment casting, otherwise known as lost-wax casting, is an industrial process based on one of the oldest known metal-forming techniques. It was developed over 5500 years ago and continues to be an integral part of metalworking to this day. This casting takes a wax outline of a part and coats it with a ceramic material. It is then heated until the wax is melted out of its center. Molten metal is then poured into the hollow ceramic mold. The metal hardens, gets broken out, and the part is made.

What are its Common Uses?

The uses of investment castings are immeasurable. Nonetheless, companies or industries engage in aerospace, power generation, firearm, automotive, military, commercial, food service, gas and oil, and energy industries use these metal components a lot. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Investment castings are even used by beverage industry equipment manufacturers and international pressure relief valve manufacturers in the oil and gas industry. As a consequence, it’s safe to say that regardless of your industry, if your business can benefit from the advantages of investment cast parts and components, they might be the perfect metal option for any of your projects.

Why Use Investment Casting?

There are several explanations for why individuals choose to use this casting. Among the reasons why companies and industries use castings are the following:

  • It produces very smooth surfaces with no parting line, requiring only minor machining.
  • It can create exceptionally complex parts that would otherwise be extremely difficult or impossible.

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Get Highly Investment Casting Today!

At Ferralloy, Inc., we supply machined investment castings to quality-controlled companies and industries. Contact us today!

Why is Stainless Steel Used in Investment Casting?

Stainless steel casting is among the few methods of the investment castings process. It is made by pouring molten stainless steel into a molder to solidify and achieve a solid and compact stainless steel material in the desired pattern. Same with other steel cast alloys, this material is a common component for casting production. When corrosion resistance and the properties of steel are needed in a certain product, stainless steel casting is the perfect option.

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Nitty-Gritty Facts About Stainless Steel Casting

Common Material Grades Used

Among the several stainless steel material grades used, the common ones are the 304, 304L, 316, 316L, 17-4 PH, and 2205 Duplex. 304 is the most extensively used austenite steel. It is commonly referred to as A2 stainless steel. Experts on investment castings also use 304L when slightly lower mechanical components are required. It is widely used by companies because of their versatility.

Application of Stainless Steel Castings

The reason why experts on investment castings use stainless steel is because of its unique physical properties. It is exceptionally resistant to corrosion, abrasion, and heat. Hence, it can be used in various ranges of industries, especially those which require materials that can withstand the severe environment. Stainless steel is used in building or construction purposes, pipe fitting, medical equipment, marine, kitchenware, and food machinery or processing.

According to investment castings professionals, stainless steel is one of the common materials used in building and construction. Modern construction uses more stainless steel when it comes to facades, roofing, and cladding. The reason for this is that it is known to have anti-vandal characteristics, low maintenance cost, and beautifully aesthetic.

As for stainless steel used in pipe fittings, it comes in various shapes and sizes. As conferred by investment castings professionals, stainless steel is used in this industry because it tends to be very convenient despite being durable and stable.

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Know More About Other Investment Castings

If you want to know more about the applications of stainless steel castings, contact us today!