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The Basic Types of Metal Castings Used

Machined castings of metals involve an intricate process wherein molten metal is poured into a mold that has a hollow cavity of the preferred geometrical shape. After such a process, it is processed to form a solidified component.Â

The word “casting” is likewise used to define or refer the part made by the machine casting process, which dates back more than 5,000 years ago. When it comes to history, this process is performed to make significant and complex metal components that would have been difficult when using the traditional manufacturing method.Â

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Metal Casting Categories You Need to Know

Permanent Mold Casting

Permanent mold machined castings are subdivided into 3 groups depending on its pattern material. These 3 groups are die casting, low vacuum/pressure, and gravity casting. This casting is sometimes called non-expendable mold casting.Â

It uses stable and long-lasting molds that are recycled after each production use. Despite using repeatable parts because of the recycled shapes, permanent mold casting can still produce simple and unique castings that, according to its preferential use.Â

Expendable Mold Casting

Since there is a non-expendable mold casting, there should also be an expendable mold casting. The latter can be divided into 2 subcategories – permanent pattern and expendable pattern. Expendable models consist of investment castings and lost foam, while stable patterns consist of ceramic mold, shell mold, plaster molding, and sand casting.

These machined castings are used as a provisional non-reusable mold to create the final cast since the frame will need to be penetrated to get the casting out. These molds are often composed of materials such as sand, plaster, shell, or ceramic.Â

Generally, these types are bonded using binders known as a bonding agent to enhance the materials’ properties. Likewise, expendable mold casting uses multifaceted and intricate geometries to produce the finished product.

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Where to Get the Best Machined Castings?

In every metal casting production, there should always be factors to consider. Such factors that need to be considered before deciding on the appropriate metal casting are the materials used, required tolerance, required quantity, and shapes or sizes of the metal component. To know more about these factors, contact Ferralloy, Inc. today!

Get Quality Machined Casting Surfaces

Producing a quality machined castings surface does not only deal with the metal used, but it is also affected by a lot of factors. It’s always a group effort that includes the customer, materials used, the process performed, and the efficiency of the producer. Since the areas that you need to finish machining require that you have a sufficient amount of metal, allowing for tolerances and removing the entire cast surface may be practical.

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How to Get the Perfect Machined Casting Surfaces

Processing Requirements

The machined castings factory is required to create the area selectively oversized to deliver sufficient material so it will be easier to machine over the entire area. This additional material is commonly known as the machine stock or finish allowance. If there is an adequate finish allowance, after you have already run the cutter over the surface, some imperfections on the surface may remain. Thus, you’ll need to scrap these parts to produce a perfect surface.

Eliminate the Porosity Issue

In heavier portions of the machined castings, porosity comes into play. It is always important to remember that cutting deep into the parts will only lead to exposure of porosity. The good thing about machined castings is that it holds tight tolerances well in such a way that you no longer have to remove certain parts of the material. As a result, you can always guarantee that you stay clear from the possibility of getting porosity issues.

Additionally, porosity issues are always present in machined castings. It’s only the process of handling or the means employed that matters. This is why it is essential that you get a supplier that carefully and meticulously works with the production factory.

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Where to Get Quality Machined Castings Surface

Examples of machining processes include cutting with the use of single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy. Aside from the fact that machining can seal surfaces and threaded holes, it also allows the production of fine and detailed components that are impossible to create through the use of casting techniques alone.

To know more about machined castings, contact Ferralloy today!

Common Machined Casting Myth Debunked

Although the process of machined castings may originally come across as rather a straightforward method, there is a lot of misinformation surrounding this industry. At Ferralloy, we believe in using the most efficient, safest, and best methods in the machine shop to guarantee that our products are cast with exceptional accuracy. Machined castings are castings that went through the process of cutting, grinding or other nontraditional machining processes. Below are some of the myths debunked to give you clearer and more concise pieces of information.

Amount of Time to Run

Although the tools and machines used in machined castings can make production comparatively simple and stress-free as they automate the job, its presence still cannot guarantee that every job will have the exact run time. Thus, it is a common misconception that all jobs require the same amount of running time.

Extremely Easy

A lot of individuals assume to think that the computerized automation of the casting and machining procedure makes it simple and faster to complete. Conversely, without the right workers for the job, the procedures will be very impossible to complete. Thus, the thought that machining is extremely easy is a myth. Every company or industry that deals with machined castings must employ people with experience, training, and skills to guarantee the accuracy, efficiency, and safety of the procedures; absence of which would mean that delivering high-quality products is highly impossible. Additionally, machine experts are accountable for monitoring and activating the loading and unloading of workpieces, the cycle of the process, and making all the indispensable adjustments.Â

Machining is Automatic

The most common myth is that machining is automatic. Notwithstanding the huge consistency that this time’s modern machined castings offer, it is highly impossible to allow the machines to do the entire job. Although previous jobs may be copied for future plans, these will still require professional help of an experienced machinist who has the ability to easily and efficiently identify and eliminate anomalies, nuances, and variations.

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Are you Searching for Exceptional Machined Castings?

Machined castings present various misconceptions. At Ferralloy, we guarantee to provide you only the best and first-class machined castings. Contact us today!

What Are Machined Castings Used For?

Machined castings include a number of services and factors. Thus, in searching for the best company to deal with this matter, it is essential that you look for an on-site and full-service machine shop with the ability to machine a variety of alloys, as well as, to machine enormous castings up to 4500 kilograms. The company must reliable and efficient journeymen machinists that are able to handle a dynamic balancing of up to 2900 kilograms with careful use of the equipment. In addition to the workforce, it is also imperative that the company must have state-of-the-art machining equipment, specialized key seater machine, and other useful machines and pieces of equipment.

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Full Service Machined Castings

What are Machined Castings used for?

When the time comes that your casting applications require machining to tight tolerances, it is important that you get a partner or acquire the services of professional companies whom you can rely on to give a reliable and unfailing high-quality service. At Ferralloy, our skilled machinists have the ability to offer quality machined castings for wear components, valve bodies, casings, split castings, diffusers, impellers, and other specialty components that you deem important. Whether your castings were placed in our sand foundry or other materials used for castings, we have the ability to offer you an assembly, finish-machined, and semi-machined results.

Specialized Impeller Machining

Since impellers have been an essential part of the casting business from the time this process was discovered, our company is known to be experts in trade and casting processes. We can immediately assemble, balance, keyway, and finish your impeller machines and machined castings without having to compromise its quality. With our experience and expertise, we have the ability to machine keyways up to 40 inches long and 4.5 inches wide. Other machine shops can justify this because of the existing and frequent contract they have with us to complete the work.

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Dimensions and Tolerances of Machined Castings

At Ferralloy, we know that tight tolerance requirements can be attained for the most crucial components like pump and compressor castings, high-pressure valves, seals, sleeves, and rotating elements for as long as the processes are carefully followed and the materials used are made of quality components. Contact us now and tell us about your casting problems!

Machined Castings | Common Misconceptions About Machined Castings

Anyone who’s in the metalworking industry knows how important the casting process is. In case you’re not familiar, this allows the creation of a wide variety of complex metal components and an equally broad selection of metal types for various industries across the globe. In some cases, these castings can even be used in the exact same form that they had when they left the mold. However, these castings usually need to be machined to serve their purpose well. Machined castings are castings that went through the process of cutting, grinding or other nontraditional machining processes. Here are some of the common misconceptions about this process:

Machining is Automatic

Despite the greater consistency that today’s modern casting methods offer, it’s still not possible to let the machines do all the work. Although past jobs can be duplicated for future projects, these will still require the expertise of a seasoned machinist who can identify and eliminate variations, nuances, anomalies, as well as dulling tools to ensure top quality results.

Machining is Extremely Easy

Many people assume that the computerized automation of the machining and casting process makes it very easy to complete. However, without the right people who have the skills, training, and experience to ensure safety, efficiency, and accuracy, the delivery of high-quality products would be virtually impossible. Machinists are responsible for activating and monitoring the cycles, loading and unloading the workpieces and making all the necessary adjustments.

All Jobs Take the Same Amount of Time to Run

Although the machines and tools can make production relatively easier as they automate the work, their presence still won’t guarantee that each job will have the same run time.

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Are You Looking for High-Quality Machined Castings?

Since machined castings can present a number of challenges, we suggest that you get your desired metal components from a company that produces high quality machined castings – Ferralloy, Inc. Contact our team of experts today!

Machined Castings | What You Need to Know About Machined Castings

Before you can truly appreciate the beauty of machined castings, you’ll need to understand the importance of the casting process as a part of metalworking. This process makes it possible to produce a wide variety of complex metal components in a vast array of metal selections for many industries. Although castings can be used in the form that they leave the mold, in most cases, castings still need to be machined to make each part even better.Â

How Does Casting Work?

During the casting process, the hot liquid metal is poured into a mold that has a cavity or a hollow cutout of the required finished shape. After the molten metal is left to cool down and solidify, it is then removed from its mold to reveal the casting form. To ensure a high-quality end product, these castings go through rigorous quality checks that usually involve a video borescope. This tool enables the manufacturer to check for residue, FOD, and other imperfections.

How Does Machining Work?

Machining refers to the process that’s utilized to cut away certain materials to alter the shape and appearance of a metal product or casting. Examples of machining processes include cutting with the use of single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy. Aside from the fact that machining can seal surfaces and threaded holes, it also allows you to produce fine and detailed components that are impossible to create through the use of casting techniques alone.

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Do You Need Machined Castings?

If your next project requires you to look for machined castings, you’ll need to get these components from a company that’s an expert in both the casting and machining techniques. Ferralloy, Inc. is the leading global supplier of engineered products and services that offer total supply chain management to a diverse metalworking customer base. Contact us today!

Investment Casting | What are the Different Methods of Machining?

Investment casting, forging, rolling, and more. There are so many ways that you can get the best out of your metal materials. Machining can do just that. Machining is a manufacturing process that cuts a component to specific dimensions that allows them to be even more precise. But, how do metalworkers machine materials?

Milling

A milling machine rotates at a very high speed. So, a metalworker will feed the workpiece into the machine and material will be cut away in small shapes. This is ideal for components that have features like holes, slots, and pockets.

Drilling

Metalworkers will use a drill bit to create a circular hole. So, drilling involves a rotary cutting tool and can perform anywhere from hundreds to thousands of rotations per minute. And, the machining will cut off little chips during this process.

Boring

Boring mills can come horizontally or vertically. Then, a metalworker can place a spindle in either orientation. Workers use this method to create clean and smooth finishes.

Facing

Facing cuts the face, or surface, of a component. This requires a planar, or flat, surface. So, the piece of metal rotates around one point. This allows for a nice and smooth face surface by removing material from the end of the piece.

Does Your Next Project Require Durable Investment Casting?

The integrity of your next industrial project relies on the durability of your metal components. At Ferralloy, we dedicate our time and expertise to creating the highest-quality metalwork. So, if you are interested in our investment casting capabilities or other services, contact us today to learn more!

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Machined Castings | What Is Machining?

The casting process is an essential part of metalworking. This process holds the ability to create a variety of complex parts in a wide selection of metals for countless industries. Sometimes, castings can be utilized in the exact form that they leave the mold. They often, however, need to be machined in order for the part to be further perfected. Keep reading to learn more about machining and to find out if you should use machined castings for your next project!

What is Machining?

Machining is a broad term used to describe the processes used to cut away materials in order to alter the appearance and shape of a casting or another metal product. Some specific machining processes include:

  • Cutting, generally using single-point or multipoint cutting tools with a clearly defined geometry
  • Abrasive processes, including grinding
  • Nontraditional machining processes that use electrical, chemical, and other sources of energy

No matter the specific process used, machining generally consists of the work piece, the tool, and the machine.

Why is Machining Used?

 Machining is used because it helps create very fine and detailed objects that would have been impossible to manufacture through casting techniques alone. Furthermore, machining has the ability to seal surfaces and threaded holes.

How Do I Get Machined Castings?

Machined castings can present some challenges. As a result, it’s important to get your parts from a company that understands both the casting and machining process. If you need machined castings for your next project, we are here to help! Established in 1978, Ferralloy Inc. can provide you with quality as-cast or fully machined parts at a competitive price and delivered on time. We are a driven organization that is committed to process improvement and customer satisfaction. Contact our metalworking experts for more information or a quote for your machined castings today!

Machined Investment Castings

The company is supplying a beverage industry equipment manufacturer with two versions of these investment cast components.  The 3 pound and 4 pound versions of the 316L investment castings were originally produced as  fabrications  from plate and bar stock.  The components were welded together and then machined.  By utilizing the investment casting process, the subassembly was able to be produced in one-piece and then finished machined.  This process change resulted in a cost reduction to the customer as well as becoming a more aesthetically pleasing component.

investment castings from ferralloy

Machined Investment Castings

Ferralloy, Inc. is producing  investment cast, internal valve components for an international Pressure Relief Valve manufacturer in the oil and gas industry.  The ‘high lift disc’ components are cast in 17-4 stainless steel, machined, and heat treated to the customer’s drawing specifications and hardness requirements.  These investment castings are purchased in lot sizes between 10,000 and 20,000 each.  Ferralloy, Inc. maintains an inventory stocking program for this customer and releases small quantities on a schedule to meet their production requirements without having to carry excessive inventory in their facility.

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