Beruflich Dokumente
Kultur Dokumente
Prepared by
The Eagle Group, Inc.
Muskegon, MI
www.eaglegroupmanufactureres.com
Table of Contents
• Introduction.....................................................3
• Knowing Your Product....................................4
• Choosing a Material.......................................5
• Choosing a Casting Process........................12
• Choosing a Supplier......................................21
FUNCTIONALITY
It is very important, when purchasing castings, to have an
understanding of how your part works. Knowing the critical
requirements of the part will help you make the right decisions
when choosing how to manufacture a part.
FLEXIBILITY IN TOLERANCES
Knowing where designs can change, and more importantly
where they can’t, will help you best design your product for
manufacturability. Deciding on the appropriate processes
will improve quality, and/or reduce cost of both the casting
and post-process machining.
○○ Resistance to Corrosion
○○ Tensile strength
○○ Yield strength
○○ Machinability
○○ Hardness
○ ○ Finishing costs
○○ Gray Iron
○○ White Iron
○○ Ductile Iron
○○ Stainless Steel
○○ Carbon Steel
○○ Copper-Based Alloy
○○ Nickel-Based Alloy
○○ Aluminum Alloy
WHITE IRON
White Iron is known for its excellent wear resistance. Some
white irons have high levels of chromium or other alloys for
increased performance of high-temperature service, or for
corrosion resistance.
Top: a comparison of cast gray and ductile iron. Bottom: a ductile iron cast pipefitting.
CARBON STEEL
Carbon steel has virtually no alloying
elements. As a result, carbon steel offers
a very high level of machinability and weldability, while
maintaining a high level of toughness.
COPPER-BASED ALLOY
Copper-based alloys, in general, have a
high level of corrosion resistance which
can make these metals a great choice
for long-term cost efficiency. Apart from
that, the properties are dependent on
A bronze cast part used
in the oil and gas industry
what other elements are in the end
combination. One of the most popular copper-based alloys
is brass, which is a made up of copper and zinc as well as
bronze–which is itself an alloy, generally made up of copper
and tin and/or lead.
ALUMINUM ALLOY
Aluminum alloy, a popular choice in die casting, is a very
castable alloy. Other great qualities of aluminum are its high
level of machinability, which can reduce costs, and its high
level of corrosion resistance, which allows aluminum to have
a wide range of applications.
○ ○ Investment casting
○ ○ Shell mold casting
○ ○ Green sand casting
○ ○ Pressure die casting
○ ○ Gravity die casting
○ ○ No-bake/ air-set casting
○ ○ Dimensional tolerances
○ ○ Cost at high volume
○ ○ Cost at low volume
○ ○ Thinnest castable sections
○ ○ Surface finish
○ ○ Ease of design change
○ ○ Alloy limitations
Bottom left: wax after it has been dipped and dried. After wax is melted out the molds are
ready to be filled with molten metal.
Bottom right: mold after molten metal has been poured and is solidifying.
Left: half of a green sand mold after having the pattern impressed on it.
Right: two halves of the mold together with a metal flask to support them being filled.
INDUSTRY STANDARD
It is important to understand what the “standard” is when
working in any industry, so you can better judge whether
suppliers’ efforts are sub par or surpassing expectations. Many
of the specifics are dependent on individual circumstances,
but there are also universal standards that all buyers should
be aware of.
The following pages offer a few key points to help you evaluate
prospective suppliers.
EXPERIENCE
When reviewing foundries, an important factor that should
be considered is how much experience they have. You
should consider: A) holistic experience in the industry; and
B) experience producing high-quality components with the
process and material you are interested in utilizing. Foundries
that are veterans in the right specialization are much more
likely to achieve success and maintain stability throughout a
production run.
QUALITY
The importance of quality cannot be stressed enough. If the
previous castings produced by the foundry are of poor quality,
then none of the other factors matter. Inadequate attention
to quality can cause losses for your organization as well as for
the foundry, so it’s in everyone’s best interest to strive for the
best quality possible. Avoiding these complications should be
top of mind when considering suppliers.
PRICE
The pricing standard differs greatly from alloy to alloy and
process to process. This makes it important to consider multiple
materials and methods in order to find the lowest overall price
for your desired service.
SOURCES
Images
http://www.castingquality.com/casting-products/pipe-fittings-casting/ductile-iron-
pipe-fittings-2.html
http://www.iron-foundry.com/gray-cast-iron-and-ductile-iron.html
http://www.travispattern.com/Green_ Sand_ Castings.php
http://www.reliablecastings.com/sand-castings_ 15.html
http://www.mdkltd.net/en/urundetay/39/ALUMINIUM-HIGH-PRESSURE-DIE-CASTING-
DIES
http://www.nonferrogieterij.nl/highpressure_ engels.htm
http://www.accurateparts.us/die-casting/
http://www.gwfoundry.com/Castings/SandCasting.aspx
http://thdick.co.uk/index.php/grades/wear_ and_ abrasion_ resistant_ cast_ irons
http://www.splicd.com/wholesale/pz6b4f59b-cz5dc8f77-304-stainless-steel-
propeller-casting-hy-mh-020.html
http://www.totalmateria.com/page.aspx?ID=CheckArticle&site=kts&NM=232
http://www.citycratemotors.com/parts/24502572-DRCE-2-Bare-Block-Gray-
Iron/682/
Information
http://www.metal-technologies.com/docs/default-source/education/
historyofmetalcasting.pdf?sfvrsn=8
http://www.inventix.com/zinc-die-casting/zinc-comparison.php http://www.afsinc.
org/about/content.cfm?ItemNumber=6890
CONTACT US
The Eagle Group
5142 Evanston Avenue
Muskegon, MI 49442
231-788-2351
All text, images and other media contained in this document are the sole
property of The Eagle Group, unless otherwise noted. Do not reproduce or
distribute this material without prior written consent of The Eagle Group.