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Foundry
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Investment Casting
Green Sand Casting
Pressure Die Casting |
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Investment Casting |
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DESIGN FLEXIBILITY
Investment casting produces near-net-shape configurations,
offering designers and engineers freedom of design in a wide
range of alloys. The process is capable of producing precise
detail and dimensional accuracy in parts weighing many pounds
or just a few ounces.
WIDE CHOICE OF ALLOYS
More than 120 ferrous and nonferrous metals are routinely cast
at Isle.
ELIMINATE TOOLING SET-UP
By offering near-net-shape configuration, fixturing costs are
substantially reduced or eliminated.
REDUCE PRODUCTION COSTS
Costly machining operations are reduced and often eliminated.
No capital equipment investment is needed to produce parts
in-house.
CUT ASSEMBLY OPERATIONS
Several parts can be made as one casting, reducing handling,
assembly and inspection costs.
REPRODUCE FINE DETAILS
Splines, holes, bosses, lettering, serrations and even some
threads can be cast.
PROCESS COMPARISON CHART |
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PROCESS |
Tool
Cost |
Unit
Cost |
Metal
Options |
Design
Freedom |
Volume
Capabil. |
Draft
Req'd |
Tolerance
Control |
Size
Range |
Surface
Finish |
Wall
Min. |
Normal
Delivery |
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Investment
Cast |
Avg. |
High |
Most |
Most |
All |
No |
Avg. |
Avg. |
Avg. |
Small* |
Avg. |
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Die Cast |
High |
Low |
Few |
Least |
High |
Yes |
Avg. |
Avg. |
Avg. |
Avg. |
Avg. |
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Forging |
High |
Avg. |
Avg. |
Least |
High |
Yes |
Poor |
Avg. |
Poor |
Large |
Long |
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Permanent
Mold |
Avg. |
Avg. |
Avg. |
Avg. |
All |
Yes |
Avg. |
Avg. |
Avg. |
Large |
Avg. |
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Plaster
Mold |
Low |
High |
Few |
Avg. |
Low |
Yes |
Avg. |
Avg. |
Avg. |
Large |
Short |
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Powder
Metal |
Avg. |
Low |
Avg. |
Least |
High |
No |
Best |
Small |
Best |
Small |
Avg. |
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Resin
Shell
Mold |
Avg. |
Avg. |
Avg. |
Avg. |
All |
Yes |
Avg. |
Avg. |
Poor |
Large |
Avg. |
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Sand Cast |
Low |
Avg. |
Most |
Avg. |
All |
Yes |
Poor |
Large |
Poor |
Large |
Short |
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*Wall
thickness "Small" with Isle's counter gravity processes.
Wall thickness is "Average" with conventional processes.
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The
Basics of the Investment Casting Process |
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WAX INJECTION
Wax replicas of the desired castings are produced by
injection molding. These replicas are called patterns.
ASSEMBLY
The patterns are attached to a central wax stick, called a
sprue, to form a casting cluster or assembly.
SHELL BUILDING
The shell is built by immersing the assembly in a liquid
ceramic slurry and then into a bed of extremely fine sand.
Up to eight layers may be applied in this manner.
DEWAX
Once the ceramic is dry, the wax is melted out, creating a
negative impression of the assembly within the shell.
CONVENTIONAL CASTING
In the conventional process, the shell is filled with
molten metal by gravity pouring. As the metal cools, the
parts and gates, sprue and pouring cup become one solid
casting. (Isle prefers to use its superior counter
gravity casting technology.)
KNOCKOUT
When the metal has cooled and solidified, the ceramic
shell is broken off by vibration or water blasting.
CUT OFF
The parts are cut away from the central sprue using a high
speed friction saw.
FINISHED CASTINGS
After minor finishing operations, the metal
castings--identical to the original wax patterns--are
ready for shipment to the customer. |
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General Tolerances |
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These
tolerances apply as a general rule of thumb. Closer tolerances
can be obtained depending on part design or the use of special
procedures or secondary operations.
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Casting Tolerances |
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U.S. |
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METRIC |
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Up
to 1.000 in. |
±.005 in. |
Up
to 25 mm |
±.127 mm |
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Up
to 2.000 in. |
±.010 in. |
Up
to 50 mm |
±.254 mm |
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Up
to 3.000 in. |
±.015 in. |
Up
to 75 mm |
±.381 mm |
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Up
to 4.000 in. |
±.019 in. |
Up
to 100 mm |
±.483 mm |
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Up
to 5.000 in. |
±.022 in. |
Up
to 125 mm |
±.559 mm |
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Up
to 6.000 in. |
±.025 in. |
Up
to 150 mm |
±.635 mm |
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Flatness
Flatness refers to single plane surface and is usually a
function of volumetric shrinkage. |
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U.S. |
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METRIC |
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Thickness |
Dish per 6 sq. inches
of surface |
Thickness |
Dish per 42 sq. cm of
surface |
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Up to .250 in. |
insignificant |
Up to 6.5 mm |
insignificant |
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.251 in. to .500 in. |
.004 in. TIR |
6.5 mm to 13 mm |
.102 mm TIR |
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.501 in. to 1.000 in. |
.008 in. TIR |
13 mm to 25 mm |
.201 mm TIR |
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1.001 in. to 2.000 in. |
.016 in. TIR |
25 mm to 50 mm |
.406 mm TIR |
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Straigtness
Tolerances for axial straightness: ±.005 in. per inch (±.127
mm per 25 mm) as cast. |
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Concentricity
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Concentricity of diameters in a
shaft is also a function of straightness. Centers will be
concentric within .005 in. per inch (±.127 mm per 25 mm) of
maximum separation.
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Centers of I.D. to O.D. will be
concentric within .003 in. per 1/2 in. (.076 mm per 13 mm)
of wall thickness. This disregards out-of-roundness, and
assumes measurements in the same plane If the concentricity
is being measured in separate planes, the requirements of
paragraph 1 above must be added.
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Roundness - Solid Bars
Roundness is a function of normal shrinkage variations in the
metal. Shrinkage variation increases with diameter and the
tolerance required increases proportionately. A general rule
of ±.005 in. per inch (.127 mm per 25 mm) may be applied.
Angles
As-cast tolerances of angles depend on their location in
casting. They range from ± 1/2° for well supported positions
to ± 2° where inherent distortion could be expected. Inclusion
of gussets and ribs often minimizes distortion and many
sections can be mechanically straightened.
Hole Positioning
±.005
in. per inch (.127 mm per 25 mm) from any single reference
point
Blind Holes
Blind holes can be cast if length does not exceed the
diameter. In nonferrous materials, blind holes under 2 in.
(6.5 mm) may be cast if length does not exceed twice the
diameter.
Parallel Sections
Controlling relationship is between length and width of the
elements being checked. To establish a specific tolerance
range for all combinations would be impossible, but a general
tolerance of .010 in. TIR per inch (.254 mm per 25 mm) may be
used.
Wall Thickness |
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U.S.
MINIMUM WALL |
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METRIC
MINIMUM WALL |
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Metal |
Small Area |
Normal |
Small Area |
Normal |
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Beryllium Copper |
.035 in. |
.050 in. |
.899 mm |
1.270 mm |
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Ductile Iron |
.035 in. |
.050 in. |
.899 mm |
1.270 mm |
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Aluminum |
.040 in. |
.060 in. |
1.016 mm |
1.524 mm |
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300 Series Stainless |
.040 in. |
.060 in. |
1.016 mm |
1.524 mm |
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Cobalt Chrome |
.040 in. |
.060 in. |
1.016 mm |
1.524 mm |
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400 Series Stainless |
.045 in. |
.070 in. |
1.143 mm |
1.778 mm |
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Carbon Steel |
.050 in. |
.080 in. |
1.270 mm |
2.032 mm |
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Roundness - Hollow Tubing
As-cast tolerances are ± .005" per inch (± .127 mm per 25 mm).
Tubular section out-of-roundness may be altered mechanically
according to wall thickness and ductility. Tolerances are as
follows: |
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U.S. |
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METRIC |
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Diameter |
Tolerances |
Diameter |
Tolerances |
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Up to 1 in. |
.006 in. TIR |
Up to 25 mm |
.152 mm TIR |
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1 in. to 1 1/2 in. |
.008 in. TIR |
25 mm to 37.5 mm |
.203 mm TIR |
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1 1/2 in. to 2 in. |
.010 in. TIR |
37.5 mm to 50 mm |
.254 mm TIR |
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2 in. to 3 in. |
.015 in. TIR |
50 mm to 75 mm |
.381 mm TIR |
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Surface
Finish |
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Metal |
MICRO-INCHES
Average RMS value |
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MICRO-METERS
Average Ra value |
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Aluminum |
60-100 |
1.50-2.50 |
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Beryllium Copper |
60-100 |
1.50-2.50 |
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Cobalt Chrome |
80-100 |
2.00-2.50 |
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300 Series Stainless |
90-125 |
2.25-3.20 |
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Carbon Steel |
90-125 |
2.25-3.20 |
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400 Series Stainless |
100-125 |
2.50-3.20 |
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Green
Sand Casting
ISLE EXPORTS (P) LTD sand owns casting foundry in India
uses green sand casting to more advanced binding processes
to manufacture a wide variety of products for many
different industries. These green sand casting parts are
high quality and very cost effective. Green sand casting
still remains one of the more popular methods for
producing inexpensive, ductile iron repeatable castings
with significant cast-in features. Because green sand
casting or ductile gray iron casting process typically
requires a large amount of labor, we are able to utilize
our low cost structures in India, and provide a low cost
final product, lower than almost any other green sand
casting manufacturer. We are also able to offer finished
machining and other secondary operations for your gray
iron casting products in India for little additional cost.
Most of our customers when utilizing our green sand
castings services prefer to use gray iron casting because
of its physical characteristics and cost. We are in no way
limited to gray iron casting. ISLE EXPORTS (P) LTD also
utilizes other metals and alloys to make the following:
• Aluminum castings
• Brass castings
• Bronze castings
•Stainless
steel castings
• Gray Iron Casting and
• Other alloy combinations
This allows us to produce a variety of gray iron castings
in India for the oilfield equipment, pipeline, valve,
heavy machinery and industrial tooling industries,
including pressure-containing components. Our green sand
casting facilities also have extensive in-house inspection
equipment including UT, RT, MAG particle examination
chemical analysis, and mechanical testing.
Gray Iron Casting Benefits
Gray iron casting (green sand casting) is suitable for a
wide range of products including many components within
the automotive, oilfield, heavy-machinery and
transportation industries. ISLE EXPORTS (P) LTD gray iron
casting is favored for many of its properties listed
below:
• High temperature properties.
• Excellent resistance to cracking
•Low Cost Finishing Options: machining, chemical-treating,
annealing, assembly, "heat-treat & machine complete".
• Prototype or full production runs
• All types of CAD files accepted
• Engineering and design assistance can be provided
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Ductile Iron Automotive
Bracket Sand Casting
Gray Iron Counter
Weight Sand Casting
Brass Sand Casting
with 2nd-op Machining
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The green sand casting process provides a quality affordable
solution for repeatable metal products with cast-in details
and features. Please be sure to contact ISLE EXPORTS (P) LTD
for your die casting, green sand casting, closed die forgings,
turnings and powdered metal low-cost manufacturing needs in
India as well. |
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Pressure Die Casting |
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ISLE EXPORTS (P) LTD high
pressure die castings facility in north India & has the
ability to design and manufacture close tolerance die cast
metal products for many different industries. We utilize
many different types of metal to produce aluminum
castings, bronze castings, copper castings and zinc
castings. Die castings require a large amount of labor, we
are able to utilize our low cost structures and provide a
low cost final product.
ISLE EXPORTS (P) LTD aluminum casting in India are able to
produce low pressure and high pressure aluminum castings.
Low pressure die casting is commonly used for larger
non-critical parts. Whereas high pressure castings which
are used for tight tolerance detailed geometry. High
pressure die castings are able to maintain tighter
tolerances and more detail than low pressure die casting
because the extra pressure utilized is able to push the
metal into more detailed features in the mold.
We are also able to offer die castings aluminum alloy with
finished machining, polishing and other secondary
operations.
Our high pressure die castings have excellent surface
finishes that are consistent dimensionally with precision
features and minimum draft. We are one stop sourcing for
engineered and aluminum die castings, zinc castings, brass
castings, and copper castings. Die casting alloys are
non-ferrous and there are a large number available with a
wide range of physical and mechanical properties to cover
almost every application a designer might need. The high
pressure die casting process provides a high quality
affordable solution for repeatable metal products. Our die
cast parts are made in India and used for many industries
including pumps and valves, propane gas, automotive,
aerospace, business and office, construction and medical.
Be sure to visit our other metal manufacturing pages for
more information on other manufacturing techniques. We
offer state of the art die casting production capabilities
in India and complete secondary finishing capabilities. |
Aluminum Conduit Body Die Casting
Aluminum Spacer Ring Die Casting
Brass Cap Die Casting
Aluminum Gas Cap Die Casting
Zinc Fastener Die Casting
Aluminum Locking Cap Die Casting
Precision Aluminum Die Casting
Die Casting with Precision
2nd Op Machining
Newer Die Casting Equipment |
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For more
information, make
enquiry or
contact us. |
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