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.

The greatest value addition we provide is our expertise to provide technical consultation for the most economical manufacturing/fabrication process. We have supported numerous customers for their process change projects from forgings, welded assemblies, sand castings to single Investment Cast component. Furthermore, our engineers understand the application of the component and can also suggest the best suited material grade. Be it any alloys of Steel ranging from Carbon Steel, Low Alloy Steel, Stainless Steel, Nickel based alloys and Cobalt based alloys, our Team can handle it with ease. We are able to extend this support because of A Lifetime of Experience in this Industry.

Design engineers are responsible for creating engineering equipment or product design which are efficient, non-destructive, durable and cost-effective for manufacturing. A Design engineer has to do a lot of research and work on prototypes. Best design is not about how it looks but also how it performs. High-end design engineers always strive for perfection in their designs. Affordability or cost savings comes second for them. But, companies still have pressure to make it cost effective and this pressure is passed onto the design engineers.

A design engineer can only be successful when they look at every aspect of product or equipment design with a detailed eye keeping in mind the end application of the part. It is very important that components used in engineering products are of high quality, perfect measurement and fits to the budget. Misfit components can destroy the whole design. Design engineers often coordinate with the procurement department for the purchase of quality and right configuration investment cast components required.

Design engineers in oil and gas, food processing, heavy and earth moving equipment, marine and general engineering industry can reach out at the details given below for more details.

Austin Alloy Cast Pvt. Ltd. is truly a global company for investment casting solutions. As a buyer from developed nations like North America and Europe, why is it important to deal with a global company who can better understand your sourcing requirements? Let’s understand here.

For the requirement of industrial products like investment casting components, companies frequently have to work with subcontracting partners in the Best Cost Countries (BCC). The outsourcing experience could be distressing due to many obstacles like cultural differences, linguistic barriers and time zone differences.

Language is one of the major obstacles that buying companies may face during the process. But, due to cultural and geo-political reasons some countries are stubborn to accept languages other than local languages. Many times this becomes an obstacle in trading with them in spite of other positive aspects of theirs.

Sales agent network of Austin Alloy Cast is efficient enough to minimise the cultural, linguistic and time zone differences. They are not only equipped with the skills and subject expert but also well versed with the gamut of trading aspects of buyer’s region. We have exclusive sales representatives in North America, South America, Europe and APAC regions who work exclusively within their territory. Their primary role is to develop new customers but they also play an important role in communication post customer acquisition. We are proud to let you know that our Team can communicate in English, Hindi, Danish, Portuguese, German, French and Japanese.

A truly global company will always offer cohesive customer services which have excellent communication, technical competency, range of services, customer focus and easy accessibility. Our customer service team at Austin Alloy Cast leave no stone unturned to offer you above mentioned qualities at customer service.

While attending investment casting queries our sales agent or customer support expert will act like a consultant who will guide you with technical details and offer the solutions instead of focusing on closing the deal.

Moreover, the solutions offered by Austin Alloy Cast are customised to match the requirements of investment casting in different regions worldwide.
Be it any sector or application, our highly qualified Team is capable of handling a wide range special alloys. We cater to worldwide customers in markets like Oil & Gas, Food Processing, General Engineering, Pulp & Paper, Heavy and Earth Moving Equipments.

Today, the world is facing innumerable environmental challenges including global warming, climate change, soil degradation, waste disposal, etc. There is an increasing risk that it will affect the generations to come and wildlife across the globe. So, it is very important for everyone on the earth to work on it. Individual or small group efforts may not be that much effective but collective effort taken by individual organisations globally can make a big impact. And working on it is not an option but a necessity.

If global manufacturing industries embrace sustainable manufacturing practices then this can bring down a major chunk of increasing threat on the earth. For this every business has to follow sustainable practices and make sure their supply chain partners follow sustainable manufacturing practices as well.

Companies are increasingly setting goals to achieve net neutrality but can a company become net neutral without the support of supply chain partners. It has become really crucial for the whole value chain to follow green and sustainable manufacturing practices.

We, at Austin Alloy Cast Pvt. Ltd. setting up an example by taking such measures at our manufacturing unit. We believe sustainability is not only about environmental impact but also equally about human welfare.

At Austin Alloy Cast Pvt. Ltd., our approach to do business is not just monetary gains but also to add value in the global ecosystem (commercial and environmental). Following are a few examples of sustainable manufacturing practices we have adapted:

Austin Alloy Cast Pvt. Ltd. is equipped with state-of-the-art infrastructure and facilities required for oil and gas investment castings. Testing lab, environment compliant manufacturing and ability to deliver in time makes Austin Alloy Cast leading supplier for investment casting components for European and North American oil and gas companies. What really sets us apart is our Team’s experience of handling a wide range of Steel alloys especially Nickel-based alloys and Duplex Steels.

Sourcing engineered components like investment castings and component suppliers for food processing, earth moving, oil and gas, medical and general engineering is a huge challenge. It becomes even more challenging when the components from two or more manufacturers look similar. Many times, two different products look similar visually but there are differences you can’t find through your naked eyes.

What defines the difference in two similar looking components?
The investment casting process is employed similarly across the globe. When it comes to differentiating between Investment Casting companies, the stand-out factors are testing facilities at manufacturing units, consistent quality and capacity to manage uncontrolled parameters.

Most of the manufacturers outsource quality testing from other service providers. Not having a testing facility at the manufacturing unit leads to delay in the manufacturing process and defects in cast components manufactured. One of the other issues industries worldwide face is that they don’t get consistent quality products supplied in each lot. You may have faced situations like when the samples provided are perfect but consignments delivered are not up to the mark. For many OEMs it’s extremely challenging to maintain consistency in Investment Casting parts. Casting companies with a strictly controlled and monitored environment can manufacture components with consistent quality. Tolerance factor, surface finish, lower dimensional accuracy and cost are some uncontrolled parameters which some OEMs have ability to control.

Austin Alloy Cast Pvt. Ltd. is leading investment casting manufacturers in India with capabilities to supply their products in Europe, North America, APAC & South America. Following featured facilities at Austin Alloy Cast Pvt. Ltd. make their investment casting components of world class quality.

Non-destructive Testing:
○ Dye Penetrant Testing
○ Magnetic Particle Inspection
○ Radiography Testing
○ Ultrasonic Testing
○ CMM

In-house NDT testing facilities like Radiography makes us less dependent on outside vendors for our testing requirements and help achieve our motto of Unmatched Customer Service by Consistent Quality and Exceptional Delivery Performance.

Skilled workers:

250+ skilled workers with years of experience and a management team with a lifetime of experience in the Investment Castings manufacturing.

Strictly controlled and monitored environment at different stages of the process including parameter tracking and control at Wax Injection, Coating & Drying, De-Waxing, Melting & Pouring, Heat Treatment, Fettling and Quality Inspection.

Gas crisis in Europe has created tension for foundries, their employees and customers. Due to gas crunch, many investment casting foundries and components manufacturers in Europe see the looming future of their businesses.

Manufacturing any kind of components (including components for oil & gas, food processing, heavy & earth moving, marine and general engineering) is energy intensive in nature.

A lot of electricity is consumed to run foundries especially for the melting process. Moreover, the investment casting process is followed by melting the metal. Casting process is one of the time taking processes and requires a proper environment. Air conditioned environment in the investment section catalyses the casting process and helps achieve the desired output. Now, making the environment air conditioned at the foundry means a lot of energy consumption.

Current scenario with industries connected to gas and energy requirements does not seem to improve in the short run. Germany, Italy, Netherland, France & Poland are amongst top importers of Gas from Russia and Russia now has indefinitely halted the gas supplies to Europe. Furthermore, The Nord Stream pipeline has been damaged recently, which makes it even more uncertain on when the gas supply will resume. This has caused not only an energy or gas crunch but also a hike in the prices. The foundries manufacturing components have to pay significantly higher energy bills than they paid earlier. Many foundries are on the verge of shutting down their business and others are reducing their production to half.

Effect of the gas crisis is on multiple levels for the European industries. One, there is a price hike and another is shortage of supply of investment casting and other metal components

European countries are working to innovate on the power generation techniques including usage of hydrogen as well as switching to thermal power plants. This inventive measure is time taking and takes years. Britain has started licensing oil and gas to boost domestic supply. But, licensing will not help reduce energy bills.

Procuring investment casting processes from countries like India and maintaining inventory of components in the home country is one of the best ways to regulate the situations for European countries. Now it is the inflexion point, where higher energy bills + higher wages (due to inflationary pressures) in Europe will outweigh Logistics cost from India + inventory carrying cost.

The reason to procure the process from India is the geo-political stability, shorter shipping distance than other Asian countries and cost effective prices.

With the suggested solution the industries will be able to minimise disruptions in their production schedules. Well planned inventory cycle with the right ordering process and production phase according to the cycle can help you manage and regulate the crisis without any effects of the gas crisis

Austin Alloy Cast investment casting company in India offers cost-effective and high quality investment casting solutions to European and North America companies.