Hot Chamber Die Casting
Also known as gooseneck casting, the hot chamber die casting process is the most popular die casting process. It is optimal for working with lower melting point alloys such as zinc, magnesium, and lead. A holding pot is filled with metal and heated with hot chamber die casting until molten by an attached or built-in […]
Mechanical Properties of Cast Iron
The mechanical properties of a material indicate how it responds under specific stresses, which helps to determine its suitability for different applications. Specifications are set by organizations such as the American Society for Testing and Materials (ASTM) so that users can purchase materials with confidence that they meet the requirements for their application. The most commonly used […]
Die Casting Process
Die casting is the manufacturing process of choice when producing high volumes of relatively complex metal parts and is widely used due to its versatility, reliability, and accuracy. Die casting eliminates all or most secondary operations needed to make a metal part; however, post-machining is common to meet tighter critical-to-function tolerances. Die casting parts can […]
Types of Iron in sand casting
Wrought Iron The first type of iron produced and worked by blacksmiths was wrought iron. It is virtually pure elemental iron (Fe) that is heated in a furnace before being wrought (worked) with hammers on an anvil. Hammering iron expels most of the slag from the material and bonds the iron particles together. During the […]
Tolerances are Material Dependent
The difficulty of manufacturing a part to a specific tolerance can be very material dependent. Generally, the softer a material is, the harder it is to hold a specified tolerance due to the material flexing while cutting. Plastics such as Nylon, HDPE, and PEEK may not hold as tight tolerances as steel or aluminum without special tooling […]
What is Molding Sand in Sand Sasting?
Molding sand has three important advantages over other mold materials: it is inexpensive, it is easily recycled, and it can withstand extremely high temperatures. Sand casting is one of the few available processes for metals with high melting temperatures such as steels, nickel, and titanium. Because of its flexibility, heat resistance, and relatively low cost, […]
Tighter Tolerances Can Change Inspection Requirements
Keep in mind how features will be inspected when adding tolerances to your parts. If a feature is difficult to machine, it is likely also difficult to measure. Certain features require specialized inspection equipment, and this may increase part costs.
Quality Control in Steel Investment Casting
Quality control in steel investment casting is integral to ensuring precise and reliable components. The process begins with a thorough inspection of wax patterns, correcting any deviations from design specifications. Subsequent checks verify the ceramic shell’s integrity and uniform coating, with a keen focus on eliminating wax residues during the dewaxing process. Critical stages like […]
Tighter Tolerances Can Mean a Change in Manufacturing Process
Specifying tighter than standard tolerances can actually change the optimal manufacturing process for your parts. For example, a hole that can be machined on a vertical mill at one tolerance range may need to be bored on a lathe in a tighter tolerance range, adding set-up costs and lead time. Even tighter tolerance requirements may require grinding […]
Tighter Tolerances = Increased Costs
It is important to keep in mind that a tighter tolerance can result in additional cost because of increased scrap, additional fixturing, special measurement tools and/or longer cycle times because the machine may need to slow down in order to hold the tighter tolerance. Depending on the tolerance call out and the geometry associated with […]
