OEMs or ODMs are responsible to deliver quality components or products to the purchasing companies. To reduce the complaints from their clients OEMs or ODMs have to monitor each equipment manufacturing process. They not only have to monitor each process but also have to take some important decisions like choosing the correct process, choosing metal quality for the components, timely delivery from foundries, etc. OEMs have to work with the best alloy casting companies which have capabilities to deliver components on time and with perfect finishing. Especially, industries like food processing, oil and gas, marine and general engineering industries need to have commercial grade quality parts with precision and accuracy.

Just converting from one manufacturing process to another can be helpful to create quality components. To understand this let’s discuss converting your components/part manufacturing from sand casting process and forging process to investment casting process.

Convert from sand casting process to investment casting process:

If your casting supplier uses a sand casting process to make parts of the equipment then it’s time to consider changing to the investment casting process. It is a myth that the sand casting process is less time consuming than the investment casting process. Sand casting, eventually might result in the same lead time as it will require more machining and which will add cost and time to the overall process. Now, with the latest technologies and expertise companies like Austin Alloy Cast can process quality components in less turnaround time. Advanced lab testing facilities, skilled workers, robust infrastructure and global sales agent network are strengths of Austin Alloy Cast Pvt. Ltd.

Convert from forging to investment casting process:

The latest machinery and equipment used in any industry today are made to use components which are complex in design. To achieve the dimensional accuracy in the components with complex design, one must opt for advanced manufacturing processes like investment casting. The forging process has a limitation when manufacturing complex geometry components. We have helped numerous customers willing to change their forged component to an Investment casting component. Below is an example of it:

This Investment casting component is used in the Oil & Gas Industry.

Secondly, a mixture of alloys are used today to manufacture parts of machinery or equipment for various reasons. Alloy versatility is much greater in the Investment casting process than the forging process. The limitation of alloy sections with forging might be restrictive for developing quality components. However, when you want to develop any parts with alloys ranging from Carbon Steel, Low Alloy Steel, Stainless Steel, Nickel based alloys and Cobalt based alloys, Highly experienced Team at Austin Alloy Cast can handle a wide range of Steel alloys with utmost ease in the investment casting process.

For industries such as oil and gas, heavy earth moving, food processing and general engineering, using quality machinery components is very important. In fact, we can say it’s the most crucial aspect for those industries. Excellent quality i.e. precise dimensional accuracy and proper surface finish of the metal components can be achieved through the Investment Casting process. The production process in the above mentioned industries might be agitated if the quality of their machinery parts are not up to the mark. Imagine what happens if machinery components fail or crack down during production! Investment casting manufacturers can help you achieve desired quality in metal components of your machinery. Sourcing from the right investment casting manufacturer is a complex process as it’s not just about the quality of metal components used in the machinery but also cost, timely delivery, ability to supply consistent quality in bulk volume, etc.

Following are a few tips for sourcing investment casting which will help you achieve desired objectives.

1. Get sample developed from the investment casting manufacturer:
Before you start a business relationship with a new investment casting manufacturer, getting samples developed for the component or parts you are going to order is advisable. By doing that you will get the exact idea of the product to be delivered later and know the capacity and expertise of product development of the manufacturer.

2. Check testing method or facilities at investment casting manufacturer:
It is very important to test the product after being ready. Manufactured products passed through various tests like x-ray test, crack detect, UltraSonic test, etc. gives you quality assurance. Testing the products from third parties increases cost and delay in delivery. It’s always better if your investment casting manufacturer has an in-house testing facility.

3. Ask turn-around time:
Get statistics of turn-around time of each product or process and total time. Consider counting logistics and inventory time and cost also. It helps you plan your delivery and other schedules.

4. Value added services:
For investment casting OEMs value added services like machining, pickling and passivation, powder coatings, tumble blasting, blackening, electropolishing, painting are often required processes. If all these value added services are available at the investment casting manufacturers, a lot of time and cost can be saved. Apart from that the same manufacturer understands the product quality and requirement very well so they can provide value added services with ease.

5. Check employee and expertise strength:
If the manufacturer has good employee and expert strength, they will be able to deliver the products in stipulated time and exact product you are looking for.

6. Understand your own requirement before sourcing or ordering:
It’s most important to understand your own requirements of quality, quantity, turn around time, cost and payment convenience, etc. Based on the requirement, you can start sourcing investment casting manufacturers matching the requirements.

7. Green production:
Nowadays, due to increasing global warming and weather change, people have started adapting green production to save earth. If you believe in the values, then it is good to check if the manufacturer has green production facilities and certifications if any.

Austin Alloy Cast Pvt. Ltd. (www.austinalloycast.com) has been offering investment casting solutions to OEMs in all the markets including North America, Europe, South America and APAC regions for years. The solutions offered are in a range of short term requirements to large and long time projects with varied requirements.

Industries such as oil and gas, food processing, heavy earth moving or marine industry require corrosion and temperature resistant components for optimised performance. Equipment like valves, piping systems, processing tools are constantly in touch with high temperature and corrosive chemicals operating in the toughest environment. Alloy selection considering the metallurgical effects for Investment Castings used in such environments is crucial for safe operations. Using the right alloy best suited for each application makes the castings cost effective.

Costs can also be optimised when the right alloy best suited for application is used.

Alloys helpful in controlling metallurgical effects like corrosion and temperature:

Nickel:
Nickel has high melting points which is 1453 degree centigrade. This makes Nickel a temperature resistant material. Also Nickel resists corrosion as the oxidation rate of Nickel is at a very slow rate. Oxidation of Nickel is done at room temperature. Nickel also has good surface stability. For these qualities Nickel is used in manufacturing castings for applications like Oil & Gas, Chemical Plants.

Cobalt:
Cobalt alloy can be used to make parts for the machineries requiring high wear and tear. It maintains its core strength in adverse environments. Cobalt is melted at above 1495 degree centigrade. Components made from cobalt are durable and strong to stand against the adverse environment. Use of Cobalt alloy in making parts for applications like rotating machineries such as compressors. It all boils down to avoid costly downtime for the end user.

Stainless Steel:
Stainless steel is melted at a very high degree. Its melting point is 1510 degree centigrade. Stainless steel is a very high corrosion and temperature resistant alloy which can be used for parts like Food Processing, Hardware, Marine markets.

Any of the above materials can be combined with other materials and used by foundries or to manufacture different parts and components. The versatility of the Investment casting industry to make a wide range of alloy components is a big advantage the process has to offer.

Apart from types of metal alloy and its quality, the process plays an equally important role in making quality Investment castings. From wax injection to coating, dewaxing, melting, heat treatment and dispatch, a controlled process is very important to make defect free high quality castings.

When Right alloy selection plus controlled process parameters is combined, The Investment casting process offers the following advantages over other metal working processes:

Austin Alloy Cast works with a perfect combination of alloy selection and process control as mentioned above. We have a Lifetime of experience in this industry and our experienced metallurgical Team can handle a wide range of alloy families like Carbon Steel, Low Alloy Steel, Martensitic Steel, Stainless Steel, Nickel Based Alloys, Duplex, Cobalt based alloys, and Heat Resisting Steels. What sets us apart is our experience in pouring and executing large orders of special alloys like CK3MCuN, CW6MC, CD4MCuN, Cu5MCuC and many more.

Our in-house Fe and Ni base Spectrometer with facility of N analysis gives us the ability to check the standards and chemical composition of the alloys poured accurately. Heat-wise Spectro reports are stored as per customer requirements and also shared upon request.

● Achieving exceptional surface finish, which results in aesthetically pleasing castings.

● Tighter tolerance and complex passages can be achieved, which are not practically possible in the Sand Casting/Forging process.

● Near net shape products, which decreases the need of extra machining hence saving costs.

For more details and enquiries, feel free to contact us. Our global network of sales agents spread across North America, Europe, South America and APAC regions is just an email/call away from you.

We pride in customer service unmatched in the industry by minimising cultural, linguistic and time zone differences.