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Custom Metal Castings

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Deeco Metals’ foundries manufacture a range of different castings employing the following casting processes: Die Casting (High or Low pressure), Investment Casting (Lost wax or Precision Cast), Permanent Mold Castings (Gravity Die Cast) and Sand Castings. We also offer Continuous or Centrifugal Castings solid and hollow bar stock.

The alloys we produce are Copper based (brass & bronze), Aluminum, Steel, Stainless Steel, Nickel based and other specialty Steels.

Depending on your specific application needs, our technical engineers and metallurgists will recommend the most suitable and economical casting method per your application.

We specialize in manufacturing metal castings for Electric Motor Housings, Pump Housings and Parts, Valve Bodies and Parts, Fire Sprinkler Frames and other fire sprinkler parts as well as many other industrial and commercial components.

Our foundries have established and effective quality assurance system that ensures accuracy and compliance to ASTM & SAE standards. Our plants use Optical Comparators, hand held measuring devices, spectrometers and other quality or mechanical measuring equipment to inspect all the castings. In addition to the casting operation, we also offer value-added services such as full or partial machining and surface conditioning such as painting, plating, powder coating & aluminum anodizing. We also offer semi or fully assembled parts or sub-assemblies.





Specifications  · Die Casting (Low & High Pressure)  · Materials  · Advantages of Die Casting  · Investment Casting (Precision Casting or Lost Wax Process)  · Permanent Mold Casting (Gravity Die Casting or Metal Mold Process)  · Sand Casting  · Sand Casting Specifications  · Shell Molding  · Bar Casting  · Centrifugal Casting

Specifications

Workable Metals

Aluminum Alloys
Cast Iron (Grey Iron, Ductile Iron, Malleable Iron)
Copper Alloys
Nickel Alloys
Special Alloys
Stainless Steel Alloys
Steel Alloys

Casting Processes

Centrifugal Casting
Continuous Casting
Die Casting (High Pressure Die Casting, Low Pressure Die Casting)
Investment Casting (Precision or lost wax process)
Permanent Mold (Gravity Die Casting or Metal Mold Process)
Sand Casting (Fully Automatic Disamatic equipment, Precision Dry Sand, Green Sand Casting, Refractory Molding, Plaster Molding, No Bake (Air Set), Shell Molding, Waterless Molding, Machine Molding & Bench Molding)
Squeeze Casting (Semi-Solid Casting)

Size Limits

From 1/4" and up

Weight Limits

From less than an ounce to 1000s of lbs.

Value-Added Services

Surface conditioning (Shot blast or vibratory finishes) and other coatings such as oil or rust preventatives, etc.
Anodize (Aluminum)
Assembly
Heat treatment to required Hardness requirements, normalizing and stress relieving
Machining
Painting
Plating
Powder Coating

Order Quantity

From small to large orders (to be determined per inquiry specs). We will recommend whatever casting method is the most cost effective for the application and still meet all quality requirements.

Typical Lead Time

Lead times can be from 12 to 18 weeks. For parts using existing tooling, shorter lead times of 8-12 weeks can be expected. Expedited service is available on request. JIT (Just In Time) inventories or Kanban stocking services are available at our warehou

Quality Assurance

Certification: Dimensional, Hardness, Elongation, Yield/Tensile Strength & most every other testing requirement can be met
Full Chemical Composition and Mechanical Certificates are standard offerings.

Compliances

We can meet several ASTM and SAE casting specifications.

Standards

ISO Compliant and Certified

Industries Served

Aerospace
Agriculture
Architectural
Auto and Truck Manufacturing Industry
Blowers
Bottling
Brick
Bushing & Bearing
Cement
Chemical
Compressors
Conveyor Systems
Cranes
Drives
Electrical
Fire Protection
Flooring
Flow meters
Fluid Power
Food
Furnaces
Gas
Gear
General Engineering
Generator Parts
Hand tools
Hardware
Hoists and Chain Lifts
Machinery
Marine
Medical
Military
Mining
Motors
Oil
Other Industrial
Packing & Packaging
Petrochemical
Plumbing
Pneumatic Tools
Pump and Impellers
Railway
Seals and Plugs
Switch Housing
Transportation
Trucking
Valve

Minimum Wall Thickness (Low Pressure Die Casting)

The process ensures dimensional stability to 0.090" wall thickness.


Die Casting (Low & High Pressure)
Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, a die casting machine and a die. The metal, typically a non-ferrous alloy such as aluminum or zinc or brass, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum and brass). However, in both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part called the casting.
The castings that are created in this process can vary greatly in size and weight, ranging from a couple ounces to 100 pounds. One common application of die cast parts are housings - thin-walled enclosures, often requiring many ribs and bosses on the interior. Metal housings for a variety of appliances and equipment are often die cast. Several automobile components are also manufactured using die casting, including pistons, cylinder heads, and engine blocks. Other common die cast parts include propellers, gears, bushings, pumps, and valves.

Capabilities

  Typical Feasible
Shapes Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex Flat Thin-walled: Cylindrical Thin-walled: Cubic
Part Size Weight: 0.5 oz - 500 lbs
Materials Metals
Brass
Aluminum
Lead
Magnesium
Tin
Zinc
Copper
Surface Finish 32 - 63 µin 16 - 126 µin
Tolerance ± 0.015 in ± 0.0005 in
Max Wall Thickness 0.05 - 0.5 in 0.015 - 1.5 in
Quantity 10,000 - 1,000,000 1,000 - 1,000,000
Lead Time Months Weeks
Advantages Can produce large parts
Can form complex shapes
High strength parts
Very good surface finish and accuracy
High production rate
Low labor cost
Scrap can be recycled
Disadvantages Trimming is required
High tooling and equipment cost
Limited die life
Long lead time
Applications Engine components, pump components, appliance housing




Materials
Die casting typically makes use of non-ferrous alloys. The four most common alloys that are die cast are shown below, along with brief descriptions of their properties. (Follow the links to search the material library).

Material Properties
Aluminum Alloys Low density
Good corrosion resistance
High thermal and electrical conductivity
High dimensional stability
Relatively easy to cast
Requires use of a cold chamber machine
Copper Alloys High strength and toughness
High corrosion and wear resistance
High dimensional stability
Highest cost
Low die life due to high melting temperature
Requires use of a cold chamber machine
Magnesium Alloys Very low density
High strength-to-weight ratio
Excellent machinability after casting
Use of both hot and cold chamber machines
Zinc Alloys High density
High ductility
Good impact strength
Excellent surface smoothness allowing for painting or plating
Requires such coating due to susceptibility to corrosion
Easiest to cast
Can form very thin walls
Long die life due to low melting point
Use of a hot chamber machine
The selection of a material for die casting is based upon several factors including the density, melting point, strength, corrosion resistance, and cost. The material may also affect the part design. For example, the use of zinc, which is a highly ductile metal, can allow for thinner walls and a better surface finish than many other alloys. The material not only determines the properties of the final casting, but also impacts the machine and tooling. Materials with low melting temperatures, such as zinc alloys, can be die cast in a hot chamber machine. However, materials with a higher melting temperature, such as aluminum and copper alloys, require the use of cold chamber machine. The melting temperature also affects the tooling, as a higher temperature will have a greater adverse effect on the life of the dies.



Advantages of Die Casting
All alloys that are die cast can be left “as cast” or supplied shot blast, Vibratory finish, plated, painted, powder coated, anodized, or acid etched or solution color Patinas. Zinc castings can be easily plated or finished with a minimum of surface preparation. Other metals may require additional surface preparation.

As cast die cast products are smoother than most other forms of castings.

Corrosion resistance of die casting alloys rate from good to high. Die castings combine many functions in one complex shaped part. Because die castings do not consist of separate or welded parts that are fastened together. The strength is that of the material, not that of threads, welds or other joining methods.

Die casting dies can produce thousands of identical castings within specified tolerances before refurbishment or new tooling is required.

Die casting provide parts which are durable, dimensionally stable, and have the feel and appearance of quality.

Die casting provides complex shapes within closer tolerances than many other mass casting production processes.

Die Castings are produced at high rates of production. In some cases very little or no machining is required.

Die castings can be produced with surfaces simulating a wide variety of textures.

Die castings can be produced with thinner walls than those obtainable by other casting methods and much stronger than plastic injection moldings with the same dimensions.

Die castings provide integral fastening areas, such as bosses and studs, which can result in assembly savings.

Holes in die casting can be cored, and made to tap drill sizes. External threads on parts can often be die cast.

Metal and some non-metal inserts can be cast in place.



Investment Casting (Precision Casting or Lost Wax Process)
Investment casting is one of the oldest manufacturing processes, dating back thousands of years, in which molten metal is poured into an expendable ceramic mold. The mold is formed by using a wax pattern - a disposable piece in the shape of the desired part. The wax pattern is dipped into ceramic slurry that hardens and becomes the mold. This process is often referred to as "lost-wax casting" because the wax pattern is melted out of the ceramic mold after it has cured and the base metal is poured into the remaining cavity. The lost-wax process uses one mold to create one part. However, since the mold produces only one part during its life, parts with complex geometries and intricate details can be created with little worry about die wear or dimensional changes.

Investment casting can make use of most metals, most commonly using aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless and carbon steel. This process is beneficial for casting metals with high melting temperatures that can not be molded in plaster or metal. Parts that are typically made by investment casting include those with complex geometry such as turbine blades or firearm components. High temperature applications are also common and include parts for the automotive, aircraft, and military industries.

Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal, and any machines needed for sandblasting, cutting, or grinding. The process steps include the following:
  1. Pattern creation - The wax patterns are typically injection molded into a metal die and are formed as one piece. Cores may be used to form any internal features on the pattern. Several of these patterns are attached to a central wax gating system (sprue, runners, and risers), to form a tree-like assembly. The gating system forms the channels through which the molten metal will flow to the mold cavity.
  2. Mold creation - This "pattern tree" is dipped into slurry of fine ceramic particles, coated with more coarse particles, and then dried to form a ceramic shell around the patterns and gating system. This process is repeated until the shell is thick enough to hold the weight of the poured metal. The shell is then placed into an oven and the wax is melted out leaving a hollow ceramic shell that acts as a one-piece mold, hence the name "lost wax" casting.
  3. Pouring - The mold is preheated in a furnace to approximately 1000°C (1832°F) and the molten metal is poured from a ladle into the gating system of the mold, filling the mold cavity. Pouring is typically achieved manually under the force of gravity, but other methods such as vacuum or pressure are sometimes used.
  4. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting. Cooling time depends on the thickness of the part, thickness of the mold, and the material used.
  5. Casting removal - After the molten metal has cooled, the mold can be broken and the casting removed. The ceramic mold is typically broken using water jets, but several other methods exist. Once removed, the parts are separated from the gating system by either sawing or cold breaking (using liquid nitrogen).
  6. Finishing - Operations such as grinding or sandblasting are used to smooth the joints at the gates. Heat treatment is also sometimes used to harden the final part.
The process is generally used for small castings, but has been used to produce complete aircraft door frames, steel castings of up to 650 lbs and Aluminum castings of up to 100 lbs. It is generally more expensive per unit than die casting or sand casting, but has lower tooling costs. It can produce complicated shapes that would be difficult or impossible with die casting, yet like that process, it requires little surface finishing and only minor machining.

Investment casting is used with almost any castable metal; however Aluminum alloys, copper alloys, stainless and steel are the most common. The advantages of investment casting are:
  • Excellent surface finish
  • High dimensional accuracy
  • Extremely intricate parts are castable
  • Almost any metal can be cast
  • No flash or parting lines
The main disadvantage is the overall cost. Some of the reasons for the high cost include specialized equipment, costly refractories and binders, much labor is required and occasional minute defects in the finished part.

Surface Finish, Part Weight & Size Parameters
In industrial usage the size limits are 3 g (0.1 oz) to about 5 kg (11 lb). The cross-sectional limits are 0.6 mm (0.024 in) to 75 mm (3.0 in). Typical tolerances are 0.1 mm for the first 25 mm (0.005 in for the first inch) and 0.02 mm for the each additional centimeter (0.002 in for each additional inch). A standard surface finish is 1.3–4 micrometers (50–125 µin) RMS.

A drawing of the component is required to determine if the weight and size can be cast.

Applications
Investment casting is used in the aerospace and power generation industries to produce turbine blades with complex shapes or cooling systems. Blades produced by investment casting can include single-crystal (SX), directionally solidified (DS), or conventional equiaxed blades. Investment casting is also widely used by firearms manufacturers to fabricate firearm receivers, triggers, hammers, and other precision parts at low cost. Other industries that use standard investment-cast parts include military, medical, marine, commercial and automotive Industries.

Capabilities
  Typical Feasible
Shapes Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex Flat Thin-walled: Cylindrical Thin-walled: Cubic
Part Size Weight: 0.02 oz - 500 lbs
Materials Metals
Alloy Steel
Carbon Steel
Stainless Steel
Aluminum
Copper
Nickel
Cast Iron
Lead
Magnesium
Tin
Titanium
Zinc
Surface Finish - Ra 50 - 125 µin 16 - 300 µin
Tolerance ± 0.0005 in ± 0.0002 in
Max Wall Thickness 0.06 - 0.8 in 0.025 - 5.0 in
Quantity 10 - 1,000 1 - 1,000,000
Lead Time Weeks Days
Advantages Can form complex shapes and fine details
Many material options
High strength parts
Very good surface finish and accuracy
Little need for secondary machining
Disadvantages Time-consuming process
High labor cost
High tooling cost
Long lead time possible
Applications Turbine blades, armament parts, pipe fittings, lock parts, hand tools, jewelry




Permanent Mold Casting (Gravity Die Casting or Metal Mold Process)
Permanent mold casting is a metal casting process that shares similarities to both sand casting and die casting. As in sand casting, molten metal is poured into a mold which is clamped shut until the material cools and solidifies into the desired part shape. However, sand casting uses an expendable mold which is destroyed after each cycle. Permanent mold casting, like die casting, uses a metal mold (die) that is typically made from steel or cast iron and can be reused for several thousand cycles. Because the molten metal is poured into the die and not forcibly injected, permanent mold casting is often referred to as gravity die casting.

Permanent mold casting is typically used for high-volume production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum , magnesium and copper alloys. However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers, and wheels.

The permanent mold casting process consists of the following steps:
  1. Mold preparation - First, the mold is pre-heated to around 300-500°F (150-260°C) to allow better metal flow and reduce defects. Then, a ceramic coating is applied to the mold cavity surfaces to facilitate part removal and increase the mold lifetime.
  2. Mold assembly - The mold consists of at least two parts - the two mold halves and any cores used to form complex features. Such cores are typically made from iron or steel, but expendable sand cores are sometimes used. In this step, the cores are inserted and the mold halves are clamped together.
  3. Pouring - The molten metal is poured at a slow rate from a ladle into the mold through a sprue at the top of the mold. The metal flows through a runner system and enters the mold cavity.
  4. Cooling - The molten metal is allowed to cool and solidify in the mold.
  5. Mold opening - After the metal has solidified, the two mold halves are opened and the casting is removed.
  6. Trimming - During cooling, the metal in the runner system and sprue solidify attached to the casting. This excess material is now cut away.
Capabilities
  Typical Feasible
Shapes Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex Flat Thin-walled: Cylindrical Thin-walled: Cubic
Part Size Weight: 2 oz - 660 lbs
Materials Aluminum
Copper
Magnesium
Metals
Alloy Steel
Carbon Steel
Cast Iron
Stainless Steel
Lead
Nickel
Tin
Titanium
Zinc
Surface Finish - Ra 125 - 250 µin 32 - 400 µin
Tolerance ± 0.015 in ± 0.01 in
Max Wall Thickness 0.08 - 2 in 0.08 - 2 in
Quantity 1,000 - 100,000 500 - 1,000,000
Lead Time Months Weeks
Advantages Can form complex shapes
Good mechanical properties
Many material options
Low porosity
Low labor cost
Scrap can be recycled
Disadvantages High tooling cost
Long lead time possible
Applications Gears, wheels, housings, engine components




Sand Casting
The Disamatic Molding equipment at our facility enables us to manufacture high volumes of sand cast parts.

Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy. Because the sand mold must be destroyed in order to remove the part (casting), sand casting typically has a low production rate. However our foundry also has automatic molding equipment (Disamatic) that speeds up the production rate.

The sand casting process involves the use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The sand mold separates along a parting line and the solidified casting can be removed. The steps in this process are described in greater detail in the next section.

Sand casting is used to produce a wide variety of metal components with complex shapes. These parts can vary greatly in size and weight, ranging from a couple ounces to several tons. Some smaller sand cast parts include gears, pulleys, crankshafts, connecting rods, and propellers. Larger applications include housings for large equipment and heavy machine bases. Sand casting is also common in producing automobile components, such as engine blocks, engine manifolds, cylinder heads, and transmission cases.

Capabilities
  Typical Feasible
Shapes Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex Flat Thin-walled: Cylindrical Thin-walled: Cubic
Part Size Weight: 1 oz - 450 ton
Materials Metals
Alloy Steel
Carbon Steel
Cast Iron
Stainless Steel
Aluminum
Copper
Magnesium
Nickel
Lead
Tin
Titanium
Zinc
Surface Finish - Ra 300 - 600 µin 125 - 2000 µin
Tolerance ± 0.03 in ± 0.015 in
Max Wall Thickness 0.125 - 5 in 0.09 - 40 in
Quantity 1 - 1,000 1 - 1,000,000
Lead Time Days Hours
Advantages Can produce very large parts
Can form complex shapes
Many material options
Low tooling and equipment cost
Scrap can be recycled
Short lead time possible
Disadvantages Poor material strength
High porosity possible
Poor surface finish and tolerance
Secondary machining often required
Low production rate
High labor cost
Applications Engine blocks and manifolds, machine bases, gears, pulleys




Sand Casting Specifications

Surface Finish

Plaster Molding: 32 gin. rms
Refractory Molding: 80 gin. rms for nonferrous castings
Sand Casting: 300 gin. rms to 500 gin. rms

Minimum Wall Thickness (Precision Dry Sand Casting)

The process ensures dimensional stability to 0.100" wall thickness.

Dimensional Tolerance

Refractory Molding: + 0.045" for castings larger than 15" in cross-section Plaster Molding: + 0.005"

Maximum Casting Weight (No Bake Casting)

20,000 lbs


Shell Molding
Shell mold casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable mold. However, in shell mold casting, the mold is a thin-walled shell created from applying a sand-resin mixture around a pattern. The pattern, a metal piece in the shape of the desired part, is reused to form multiple shell molds. A reusable pattern allows for higher production rates, while the disposable molds enable complex shapes to be cast. Shell mold casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal.

Shell mold casting allows the use of both ferrous and non-ferrous metals, most commonly using cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys. Typical parts are small-to-medium in size and require high accuracy, such as gear housings, cylinder heads, connecting rods, and lever arms.

The shell mold casting process consists of the following steps:
  1. Pattern creation - A two-piece metal pattern is created in the shape of the desired part, typically from iron or steel. Other materials are sometimes used, such as aluminum for low volume production or graphite for casting reactive materials.
  2. Mold creation - First, each pattern half is heated to 175-370°C (350-700°F) and coated with a lubricant to facilitate removal. Next, the heated pattern is clamped to a dump box, which contains a mixture of sand and a resin binder. The dump box is inverted, allowing this sand-resin mixture to coat the pattern. The heated pattern partially cures the mixture, which now forms a shell around the pattern. Each pattern half and surrounding shell is cured to completion in an oven and then the shell is ejected from the pattern.
  3. Mold assembly - The two shell halves are joined together and securely clamped to form the complete shell mold. If any cores are required, they are inserted prior to closing the mold. The shell mold is then placed into a flask and supported by a backing material.
  4. Pouring - The mold is securely clamped together while the molten metal is poured from a ladle into the gating system and fills the mold cavity.
  5. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting.
  6. Casting removal - After the molten metal has cooled, the mold can be broken and the casting removed. Trimming and cleaning processes are required to remove any excess metal from the feed system and any sand from the mold.
Capabilities
  Typical Feasible
Shapes Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex Flat Thin-walled: Cylindrical Thin-walled: Cubic
Part Size Weight: 0.5 oz - 220 lb
Materials Metals
Alloy Steel
Carbon Steel
Cast Iron
Stainless Steel
Aluminum
Copper
Nickel
 
Surface Finish - Ra 50 - 300 µin 32 - 500 µin
Tolerance ± 0.15 in ± 0.006 in
Max Wall Thickness 0.06 - 2.0 in 0.06 - 2.0 in
Quantity 1,000 - 1,000,000 100 - 1,000,000
Lead Time Weeks Days
Advantages Can form complex shapes and fine details
Very good surface finish
High production rate
Low labor cost
Low tooling cost
Little scrap generated
Disadvantages High equipment cost
Applications Cylinder heads, connecting rods




Bar Casting

Bar Casting Process

Continuous casting, also called strand casting, is the process whereby molten metal is solidified through a metal or water cooled graphite die into a "semi-finished" bronze or brass solid bar or hollow bar. Solid or hollow shapes in lengths are also produced. It is also used for the manufacture of steel billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots. Since then, "continuous casting" has evolved to achieve improved yield, quality, productivity and cost efficiency. It allows lower-cost production of metal sections with better quality, due to the lower costs of continuous, standardized production of a product, as well as providing increased control over the process through automation. This process is used most frequently to cast steel (in terms of tonnage cast), however, Aluminum and copper are also continuously cast.

Continuous Casting Materials

Bronzes and brasses that are now widely continuously cast into hollow bar or solid bar for bushing and bearing applications or wear plates. Common Bronze alloys are follows:
Leaded Tin Bronzes: CDA 932 (SAE 660), 936 (Modified SAE 64), 905, 903, 922, 836 (85/5/5/5 - Gun Metal), Etc.
Manganese Bronzes: CDA 863, 862, 865
Nickel & Aluminum Bronzes: CDA 954, 955, 959, Etc.
Phos/Bronzes: 510, 544, 524, etc., which are then drawn to obtain their mechanical properties. They are referred to wrought phosphor bronze bar stock. These can only be produced in solid form.
Brass & others on request.
Deeco Metals most often supplies machined parts in bronzes.

Standard Sizes and Shapes (Continuous Castings)

Plates: All, specials
Rectangles: From 1/4" to 6" thick x 10" standard and up to 20" wide
Solids: 1/2" to 12" diameter
Squares: Standard up to 6" square and other sizes cut to order
Tubing: 1/2" ID x 1" to 0.1410" x 16" GD


Centrifugal Casting
Centrifugal casting, sometimes called rotocasting, is a metal casting process that uses centrifugal force to form cylindrical parts. This differs from most metal casting processes which use gravity or pressure to fill the mold. In centrifugal casting, a permanent mold made from steel, cast iron, or graphite is typically used. However, the use of expendable sand molds is also possible. The casting process is usually performed on a horizontal centrifugal casting machine (vertical machines are also available).

Capabilities
  Typical Feasible
Shapes Thin-walled: Cylindrical
Solid: Cylindrical
Thin-walled: Complex
Solid: Complex
Part Size Diameter: 1 - 120 in.
Length: Up to 50 ft.
Weight: Up to 5 tons
Materials Metals
Alloy Steel
Carbon Steel
Cast Iron
Stainless Steel
Aluminum
Copper
Brasses & Bronzes
Nickel & Nickel Alloys
 
Surface Finish - Ra 63 - 500 µin 32 - 500 µin
Tolerance ± 0.03 in ± 0.015 in
Max Wall Thickness 0.1 - 5.0 in 0.1 - 5.0 in
Quantity 100 - 10,000 1 - 10,000
Lead Time Weeks Days
Advantages Can form very large parts
Good mechanical properties
Good surface finish and accuracy
Low equipment cost
Low labor cost
Little scrap generated
Disadvantages Limited to cylindrical parts
Secondary machining is often required for inner diameter
Long lead time possible
Applications Pipes, wheels, pulleys, nozzles




 MORE IMAGES 

·  Aluminum Ingots for Die Casting Furnace

·  Anodes - Continuous Cast

·  Anodes - Copper & Brass Continuous Cast

·  Auto - Aluminum Die Cast Machined Part

·  Bar Stock - Bronze Conticast

·  Bar Stock - Bronze Hollows

·  Bar Stock - Bronze Packed

·  Battery Terminal - Brass Plated

·  Battery - Terminals

·  Beer Keg Valve Body - Brass Die-Casting

·  Brass Billet ContiCast - Machined for Extruding Tube

·  Brass Billet - Conticast

·  Brass Billet for Extruding

·  Brass Extrusion Billet - Conticast

·  Bronze Investment Cast Switch Part (Bottom)

·  Bronze Sand Castings

·  Cap and Body - Stainless Polished Assembly

·  Cap and Head - Investment Cast Bronze Parts

·  Case Cap - Manganese Bronze Sand Casting

·  Casing - Sand Cast and Machined Steel

·  Cast Iron Painted Castings

·  Cast Iron Parts

·  Centrifigal Castings

·  Centrifugal Cast - Large Bronze Rings

·  Centrifugal Cast - Tube Cooling

·  Centrifugal Cast - Tube Removed From Die

·  Centrifugal Casting Tube

·  Centrifugal Casting

·  Centrifugally Cast Stainless

·  Centrifugally Cast Large Bronze Ring

·  Centrifugally Cast Auto Feed

·  Centrifugally Casting or Spun Casting

·  Centrigual Cast Bronze Gear Machining

·  Clamps of Steel Sand Cast

·  Cleaning and Cutting Sand Castings

·  Ceaning CI Parts of Burs

·  Cleaning Grind Sand Castings

·  Cleaning Sand From Castings

·  CMM Inspection Equipment

·  CNC Lathe

·  CNC Machining Center

·  CNC Machining

·  Conticast Bar Being Pulled From Furnace

·  Coppe Sand Cast Water Jacket

·  Cores Ready for Automatic Disamatic Casting

·  Cover - Aluminum Die Casting Unmachined

·  Cover Plate - Cast Iron Machined

·  Cover -Sand Cast Iron Painted

·  Covers - Die Cast

·  Cutting Castings From Tree

·  Die Castings Ready to Machine

·  Die Cast Housing Ready for Inspection

·  Die Casting Machine - Zinc

·  Die Casting Machine

·  Die Casting Machine - Aluminum Parts

·  Die Casting Machine - Large

·  Die Casting Machine - Medium

·  Die Casting Machine - White

·  Die Casting Ready for Machining

·  Die Casting - Untrimmed

·  Die Castings for Cleaning Flash

·  Die Castings - Just Cast

·  Die Castings - Ready for Machining

·  Dipping Into Ceramic Powder

·  Dipping Into Slurry

·  Door Hardware - Die Cast Polished & Assembled

·  Elbow Casting

·  Elbows - Large Sand Casting Ready for Grinding

·  Elbows - Large Sand Castings Ready for Shot Blasting

·  Elbows - Sand Castings

·  Elbows - Sand Casting Shot Blast Cleaned

·  Electronic Heat Sinks

·  Electronic Part - 5 oz

·  Engine Block Machined and Sleeved

·  Eye Bolt - Steel Casting Machined

·  Family of Cast Iron Parts

·  Fire Spinkler Frames - Brass Die Cast Ready for Clipping

·  Fire Sprinkler Frame - Brass Die Casting Chromed

·  Fire Sprinkler Frames - Brass Die Cast

·  Fitting - Investment Cast

·  Fitting - Machined

·  Fitting - QA Inspecting - Machining

·  Fitting - SS Investment and Machined

·  Fittings for Pipes - SS Investment Cast Machined

·  Fittings - Pipe Stainless

·  Fittings - Stainless

·  Flasks - Adding Slurry Onto Wax Mold

·  Flasks Being Created Over Wax Tree

·  Flasks Being Filled by Molten Metal

·  Flasks Being Filled With Molten Metal

·  Flasks Made Up of Slurry and Powder

·  Flasks Moving to Process

·  Flasks - Red Hot and Cooling

·  Flasks - Red Hot with Metal

·  Flat Bar - CC Bronze for Wear Plates

·  Foundry Furnace for Copper

·  Foundry Furnace Melting Cu Scrap

·  Foundry Furnace

·  Foundry Investment Casting

·  Foundry - Jobbing Parts Sand Casting Workshop

·  Foundry - Molten Copper

·  Foundry - Pattern Storage

·  Foundry - Patterns Being Repaired

·  Foundry - Sand Castings

·  Foundry Pictures

·  Foundry - Poured Metal in Sand Mold

·  Foundry - Pouring into Sand Molds

·  Foundry - Pouring Molten Metal

·  Foundry - Sand Cast Mold Bottom

·  Foundry - Sand Cast Mold Top

·  Foundry Sand Casting Division

·  Foundry Sand Casting

·  Foundry Sand Core Production

·  Foundry - Semi-Automatic Sand Casting Production Line

·  Foundry - Wooden Patters

·  Furnace - Pouring Iron Into Mold

·  Gas - Aluminum and Zinc Die Cast with Brass Forging

·  Gas Burner Cast and Machined

·  Gas Burner - CI Painted

·  Gas Cap - Zinc Machined Die Casting

·  Gas Regulator Parts - Zinc Die Castings

·  Gauge - Stainless Investment Cast Machined Parts

·  Gauge Parts - Investment Castings from Bar Stock Parts

·  Gear Box Bodies - Sand Cast

·  Glass Molds - CC-D Shape XX Alloy

·  Gauge Housing - Machined and Painted

·  Hand Tool - Die Cast Parts

·  Hand Wheels - Cast Iron

·  Handle - Zinc Die Cast

·  Heat Treatment Ovens

·  Hinge - Investment Cast Machined Polished and Assembled

·  Hook Cast In Manganese Bronze

·  Hook Sand Cast Assembly

·  Housing - CI Machined Part

·  Housing - Grey Iron Machined Part

·  Housing - Sand Cast

·  Housings - Die Cast and Machined

·  Housings - Stainless Machined

·  Hub - Cast Iron Machined Painted and Assembled

·  Hub - Cast Iron Machined and Painted

·  Hub - Cast Iron Machined

·  Impellor - Sand Castngs

·  Inspecting Bronze Castings

·  Inspecting Castings

·  Inspecting CMM In Quality Inspection Department

·  Inspection - Pressure Testing Castings

·  Inspection - Quality Department

·  Internal Gear - Investment Casting

·  Investment Cast - Bronze Switch Part Top

·  Investment Cast Parts

·  Investment Cast Parts Lot

·  Investment Casting Process

·  Investment Castings

·  Iron Bar - Continuous Casting

·  Joint Fitting

·  Lab Work Test on Foundry Samples

·  Lamp Post Part - Aluminum Investment Castings

·  Lamp Posts Parts - Aluminum

·  Large Bolts - Investment Cast and Machined

·  Light Housing - Aluminum Die Casting

·  Light Housing - Die Cast Alu

·  Light Housing - Die Cast

·  Machine Beds

·  Machine Part

·  Machine Ruler - Investment Cast

·  Machine Shop - CNC Machining Castings

·  Machine Shop for Bronze Sand Castings

·  Machine Shop - Tapping Machines

·  Machined Parts from Investment Casting

·  Machined Wheel Housings - Painted Sand Casting

·  Machined Wheels

·  Machining Die Castings

·  Machining Wheels

·  Manifold - Ductile Iron Casting Machined Painted

·  Manifold - Ductile Iron Machined and Painted

·  Manifold - Iron Castings

·  Manifold - Stainless Casting

·  Manifolds - Ductile Sand Cast

·  Manifolds - Stainless

·  Marine - Aluminum Port Hole Sand Cast

·  Marine Boat Cleat - SS Polished

·  Marine Hardware

·  Marine Hatch Handles - Machined Polished

·  Marine Hatch Handles - SS Polished

·  Marine Pipe Fittings

·  Marine Port Hole - Bronze Sand Cast and Polish

·  Marine Port Hole - Rec Bronze Machined and Polished

·  Marine Port Hole - Sand Cast Brass Complete

·  Marine Propeller - Alu Die Cast Unworked

·  Motor Housing - Aluminum Die Cast Machined

·  Motor Housing - Aluminum Die Casting Machined

·  Mounting - Die Casting

·  Muflet - Die Casting

·  Nickel Alloy Castings

·  Nuts - Aluminum Before Machining

·  Pad Eye - Machined and Polished Part

·  Painted Cast Iron Sand Castings

·  Permold - Aluminum Casting Parts

·  Permold Casting - Alu Parts

·  Permold Casting

·  Pipe Flange - Stainlesss

·  Pipe Housing Parts

·  Plant - Continuous Casting

·  Plate - Sand Cast and Machined

·  Polishing Line

·  Pressure Die Casting - Brass Machining Parts

·  Pressure Die Casting - Brass Parts

·  Pulley - Cast Iron

·  Pulley - Cast Iron Machined

·  Pulley - Machined

·  Pulley

·  Pump Bodies

·  Pump Body

·  Pump Body - Ductile Iron Machined Painted

·  Pump Body - Cast

·  Pump Cast Parts

·  Pump Housing

·  Pump Housing Top

·  Pump Housing Cast in SS

·  Pump Housing - Injection Molded Wax

·  Pump Impeller - Investment Cast

·  Pump Impellers

·  Pump - Investment Cast Parts

·  Pump Parts Ready for Packing

·  Pump - Silicasol Casting

·  Pump - Stainless Parts

·  Pump - Steel Impeller Painted

·  Pump Turbine

·  QA CMM - Inspection Quality Department

·  QA In-process Inspection Tables

·  QA Salt Spray Test

·  Rack - Cast

·  Rack Fittings - Die Cast

·  Raw Material - Scrap Copper Wire for Melting

·  Raw Material - Scrap Copper Wire

·  Raw Materials - Ingots of Pig Iron

·  Raw Materials - Scrap Brass Turnings Used in Foundry

·  Raw Materials - Scrap from Foundry Risers and Runners

·  Raw Materials - Scrap Used for Copper Alloy Castings

·  Raw Material - Scrap for Copper Alloy Castings

·  Sand Cast Iron Machined Assembly

·  Sand Cast Iron Parts

·  Sand Cast Parts

·  Sand Castings Before Cleaning

·  Sand Castings Before Cutting and Cleaning

·  Scrap Bronze - Ready for Melting

·  Semi Continuous Cast HC Copper Cake

·  Shapes - Conticast

·  Shapes - Continuous Cast

·  Shapes - Continuous Cast Bronze

·  Simple SS Part - Investment Cast

·  Small 1 Inch Assembly

·  Small 1 Inch Stainless Casting

·  Small 1 Inch Machined Part

·  Spray Parts Nozzle - Stainless

·  Sprocket Casting

·  SS Machined Casting

·  Stand - Ali Die Cast

·  Steel Investment Cast Part

·  Steel Weldment Bottom Converted to Bronze Investment Casting

·  Steel Weldment Top Converted

·  Switch Plates

·  Vale Body - Die Cast

·  Vale Parts Just Sand Cast

·  Valve Ball Body Casting

·  Valve Ball Part Machined

·  Valve Ball Part

·  Valve Bodies - Cast Iron

·  Valve Body - Ali Die Casting

·  Valve Body Castings

·  Valve Body Machined

·  Valve - Bronze Castings Being Machined

·  Valve - Bronze Sand Castings Machined

·  Valve Cast Component

·  Valve - CI Sand Cast

·  Valve - CI Sand Cast Part

·  Valve Part - Die Cast Brass and Aluminum Painted

·  Valve - SS Machined Part

·  Valve Handle - Brass

·  Valves Ball Bodies Castings

·  Various Ali Die Cast Covers

·  Warehouse and Dispatch Area

·  Water Fountain Light

·  Water Meter - Brass Body

·  Water Meter - Brass Die Cast Bottom Plate

·  Water Meter Cover

·  Water Meter Housing - Brass

·  Water Meter Housing - DZR Brass Die Cast

·  Water Meter Housing

·  Water Meter Lids

·  Water Meters CI Valve Covers

·  Water Meter Bodies for Machining

·  Watermeter Brass Die Cast Parts

·  Water Meter - Permold Gravity Die Casting

·  Wax Aluminum Dies Storage Room

·  Wax Assembled Trees

·  Wax Injected Mould Parts

·  Wax Injection Equipment

·  Wax Injection Molded Parts

·  Wax Model and Cast Parts

·  Wax Molds Curing in Controlled Room

·  Wax Molds Curing

·  Wax Mould and Metal Casting

·  Wax or Foam Molds

·  Wax Parts Being Assembled on Tree

·  Wax Parts on Trees

·  Wax Pump Mold

·  Yatcht Assembled Polished Parts

·  Zinc Pressure Die Cast Parts


 DOWNLOADS 

Conversions of Fraction to Decimal
(PDF, 36KB)

Hardness Conversion Table
(PDF, 55KB)

Metal Weight Conversion Table
(PDF, 29KB)

Wire Gauge Chart
(PDF, 33KB)

Common Metric Equivalents
(PDF, 39KB)


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