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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.

aluminum castings investment

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.

aluminum castings investment

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!

Alloy Casting for Pressure Valves

Aside from the fact that alloy castings are more cost-effective than other methods, casting also allows you to create certain parts that are designed according to your requirements. To give you a better idea about how beneficial it is for your business to choose alloy castings for pressure valves, read on.

alloy castings

Advantages of Using Alloy Castings

Flexibility

Alloy castings are shaped as liquid and possess features like low melting point, high fluidity, and good as-solidified strength. They are widely used in the form of die castings and general-purpose sand castings. Additionally, this type of castings is used where fluidity, good corrosion resistance, and rigidity are of greater importance than strength.

Unquestionably, the most widely used alloys are those containing between 9.0% to 13.0% silicon, which occasionally have small amounts of copper. Silicon increases fluidity and decreases shrinkage of molten aluminum alloy so that castability is high and intricate shapes and complex geometry can be cast. Hence, it becomes easier for alloy castings to be used in creating pressure valves.

Lightweight Yet Powerful

Although alloy steel castings are extremely lightweight, their sturdiness allows them to be effectively applied for companies that are involved in the manufacturing of vehicles. Furthermore, when it comes to the production of high-performance wheels, this type of casting can be your best option.

Durable

The calcium, zirconium, nickel, and cerium components in alloy castings make them highly durable compared to other options. You can expect your alloy castings to exhibit better resistance to wear and tear, as well as high heat.

alloy castings

 

Applications of Alloy Castings

Most alloy castings are applied in components that require intricate castings. This type of casting is widely used in water jackets, valve bodies, pressure-tight components, heavy-duty pistons for diesel engines, cylinder-heads for liquid and air-cooled engines, and automobile pistons.

If you want to know more about the applications of alloy castings, contact Ferralloy Inc. through this link!

Get Raw Materials with Ease

Engineering production units use numerous types of raw materials in their operations for giving an exceptional shape to a new product. Occasionally, it becomes a big challenge to get the essential goods in local markets due to high demands, costs, and other factors. This concern normally affects the entire manufacturing process which results in different problems. Nowadays, global sourcing allows manufacturing companies to attract various organizations which mainly depend on engineering products.

global sourcing

Why is Global Sourcing Essential?

Purchasing Raw Materials is Made Easier

Global sourcing allows manufacturing companies to purchase various types of materials from other countries to enhance their production levels. There are numerous suppliers who provide supply chain management services for a lot of industries to gain major benefits. With this method, engineering firms can focus more on reducing costs on their labor and raw materials for achieving the best results.

Nonetheless, it is important to research the suppliers from the internet before choosing services.

Materials Often Subjected to Global Sourcing

It is essential to know how to purchase the materials needed from other countries that will ultimately help you overcome complex issues. Below are the materials often purchased through global sourcing.

Zirconium

It is a silver-gray metal used in ceramic industries, food packaging, furnace linings, and other applications. Zirconium is a highly resistant product that gives ways for meeting exact needs in the manufacturing process.

Inconel Alloys

These are often purchased by chemical manufacturing companies to improve the structure of a product at maximum temperature.

metal global sourcing

Global Sourcing Keeps the Process Going

Most of the time, companies engaged in casting and forging processes are the ones who greatly benefit from global sourcing. Since these procedures use different kinds of materials, easy access can keep things going. If you want to know more about the benefits of global sourcing, contact Ferralloy Inc. 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!

Continuous and Lost Foam Casting

There are several types of machined castings and the less discussed methods are continuous

and lost foam casting. Both have complicated technological processes and complex technical characteristics. Here are the facts on the two types of castings.

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Why Choose These Types of Castings

Continuous Casting

It is a state-of-the-art casting method that involves the continuous pour of molten metal into a crystallizer. Once it solidifies, the casting is continuously pulled out from another end so the metal can obtain any specific length.

When it comes to technical characteristics, continuous casting can enhance production efficiency. Likewise, because of the simplified techniques, this process can dramatically reduce the desired production area and labor intensity. Another advantage why using continuous casting is recommendable is the fact that it offers good mechanical properties, uniform structure, and dense crystals.

Continuous castings are often applied in productions with cross-sectional shapes like pipes, rod billets, slabs, and ingots. This type of casting is also used in components made of magnesium alloys, aluminum alloys, copper alloys, iron, and cast steel.

Lost Foam Casting

Otherwise known as a solid casting, lost foam casting is a contemporary method that involves a combination of foam or paraffin models akin to the shape and size of the casting to produce a model cluster. After drying and brushing the refractory coating, it is buried in dry sand and poured under intense pressure to vaporize the model.

As for its technical characteristics, lost foam casting can reduce production costs and investment. It also offers a high degree of freedom during the production process, flexible design, and no parting surface.

As for application purposes, it works best in producing different sizes of precision castings with complicated structures. The best thing about this type of casting is that there are no restrictions on the kind of alloy used.

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Learn More About the Other Types of Machined Castings

Apart from lost foam and continuous casting, there are also other types of casting processes such as squeezing die casting, vacuum die casting, and many more. Contact our experts at Ferralloy Inc. to know more!

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.

Near Net Shapes of Seamless Rolled Rings

Seamless rolled rings offer numerous advantages, such as using less material to be machined to achieve the final machined part. However, one of the most notable factors why industries opt for these rolled rings is the near net shape factor. Aside from the cost reduction, companies or manufacturers who use the seamless rolled rings process can maintain constant durability and strength in the product. 

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Benefits of Near Net Shapes

Cost Reduction

By using seamless rolled rings, your company can reduce costs in several ways. For instance, the process involves less wear factor in the machining equipment and requires lesser machinery hours. Additionally, there is less input component needed to design and create the ring.

Since near-net designs of seamless rolled rings substantially reduce costs, it became popular in aerospace industries. Because of the high cost of several aerospace supplies and resources, enterprises engaged in this sector often look for cost-effective substitutes.

Reduced Waste Material

Seamless rolled rings allow you to save on waste and recycle disposal costs. Hence, most manufacturing industries always guarantee that the process should produce near net shapes to reduce waste materials costs.

Why Choose Near Net Shape Manufacturing

Near net shape, manufacturing is the perfect solution for those looking to cut back on manufacturing costs. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any machining time, you can save on production costs. It also takes less time to produce near net shapes.

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Get Seamless Rolled Rings Today!

Ferralloy Inc. is composed of engineers who are highly skilled in designing and create forged materials. They are used to dedicating their time to create durable and reliable metal works. Among the several developing industries and companies, Ferralloy Inc. is a leader in producing and near net-shaped metal workings with ring geometry. 

To know more about what we can offer, contact our team today through this link. We assure you that only quality and lifelong metal works will be provided. 

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.

where is the best investment casting?

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.

where can I get the best investment casting?

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!

Comparing Die Casting and Investment Casting Methods

Die casting, and investment casting are 2 of the foremost important types of casting. Die casting is a method wherein molten metal is created and formed into a mold cavity by way of enforcing high pressure. On the other side, investment casting is a process that involves the injection of wax into the aluminum cavity. Both die casting and investment castings have different advantages and disadvantages. Read on to know more.

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How Does Die Casting Differ from Investment Casting?

Die Casting

As stated earlier, die casting differ from investment castings in such a way that the former involves a metal casting procedure. It is categorized by the use of a mold cavity to apply high pressure to the molten metal. These molds are then machined, designed, and created from higher strength alloys. Additionally, the majority of die castings are iron-free.

Among the notable advantages that clients opt to choose to die castings over investment castings are the following: it has an exceptional economic effect, high productivity, and creates good product quality.

Investment Castings

Investment castings involve an exact and strict casting process through the use of the lost-wax process to create components in the metal cast alloys. This process is known to be very accurate, creating components with accurate dimensions and smooth surface finishes. With this process, the machining and finishing processes are reduced. Thus, it will be more cost-effective without even compromising the quality. The only downside when choosing investment casting is that it is more expensive than sand casting.

Other Differences

Casting predominantly includes special casting and sand casting. Investment casting is included under special casting while die casting is considered pressure casting, which is another major type with the same level as investment castings. As for the cost, die casting costs are higher than investment casting since the former involves post-processing operations and high-processing costs. However, when large production is needed, die casting is recommended because investment casting is a manual process that requires more time and cost.

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Where to Get Die Casting or Investment Castings?

If you’re planning to get components or materials that underwent die casting or investment casting process, contact Ferralloy today for more inquiries!