Month: August 2020

A Guide On the Stainless-Steel Lost Wax Casting

Over the years, manufacturers greatly rely on the stainless steel lost wax casting process to create high-quality parts and components. Stainless steel investment casting allows the manufacturing of complex shapes having high-dimensional accuracy.

In addition, stainless-steel is an excellent material that offers engineers freedom in terms of material choice and product design. It is possible to include the consumer’s demands and specifications into the casting process.

Understanding the wax casting process for stainless steel is important. Therefore, in the course of this article, we are going to discuss all the steps that are part of the stainless-steel lox wax casting process. So, without any further delay, let us get started!

The breakdown of Stainless Steel Lost Wax Casting Process

Below are the steps that are part of the process.

Moulding Making in Lost Wax Casting

The first step in the process of stainless-steel lost wax casting is the creation of the mould. Manufacturers use these moulds to inject wax patterns. They have the same dimensions as that of the final stainless-steel castings.

In order to make sure that the wax pattern is of high quality, it is important to focus on the mould’s surface roughness value along with the high-dimensional accuracy. Ensure that the surface roughness value is minimum.

Aluminum alloy is the top priority for most stainless-steel casting companies. They use it as a mold material due to the benefits it offers including reusability, easier managing, etc.  In case, you want the alloy to be of extremely high-quality, you can ask the manufacturer to choose the aviation aluminum as the material used in the mould.

If you don’t ask for a certain alloy, the casting manufacturers would use the regular aluminum as it would cost them less.

Wax Pattern Injection

Next comes the injection of the wax pattern into the mould cavity. You need to press only the treated wax paste into the mold cavity. Wait for the ice water to be condensed, then you can take out the wax paste from the ice water machine.

Next, you would have to put the profile into a pool for a certain time frame. Eventually, you will end up with a single wax pattern for the inspection and dressing purpose. You can consider the wax pattern as the die-cast part.

Repairing the Wax Pattern

Since the wax pattern’s quality will have a direct impact on the final stainless-steel casting, therefore, you need to pay extra attention to it. You need to control the temperature of the wax pattern workshop. Ensure that it remains consistent as it would minimize the wax patterns deformation.

Also, it is important that you inspect the wax pattern’s surface quality especially for the ones that have flash, burrs, and parting lines. For the success of stainless steel lost wax casting, manufacturers need to repair all these issues in an effective and efficient manner.

Tree Assembly in Lost Wax Casting

After the manufacturer completes the pattern repairing, it is time to move onto the tree assembly process. After enhancing the product quality of the wax pattern, a single wax pattern is welded as well as fused on a casting system (pre-determine). This is to make the wax-pattern assembly.

It is possible to use one wax module for the welding of about 2 ~ 80 wax patterns. With the tree forming scheme, the manufacturer is able to find the molten stainless-steel utilization rate as well as the yield of products.

Therefore, manufacturers need to carefully consider the design of the tree-forming scheme. Also, they should keep in mind that the tree-forming idea should be effective for the reuse of the wax as well as its recovery.

Wax Pattern Clearing

Wait for about 45 minutes before cleaning the wax modules present behind the group trees. It is important to remove the grease and the wax crumbs present on the surface of the wax modules. After cleaning, you can make hanging slurry and shells.

Cleaning the modules would enhance the adhesion of developing the shells. Take a cleaning flood and dip the module into it from about three times. The total time the process takes should be roughly 4s. Once you take the module out, you need to dry it. Use compressed air for this particular purpose.

After completely drying the modules, you can make shell by sizing.

Making of Shell

Manufacturers put the wax patterns into the shell making shop, after coating them. In terms of drying, the surface layer dries naturally, however, for the back and transition layer, manufacturers rely on artificial methods.

They would use a rotary air-drying machine in order to enhance the speed of the drying. For small stainless-steel casting, repeat the coating for about 5 to 7 times. In the case of bigger casting, repeat coating for about 6 to 9 times.

Repeat the coating it the wax forms a hard shell of 7 to 15 mm. This would provide it with the right amount of strength.

Dewaxing and Waxing

Put the shell backward in the dewaxing steam axe. Manufacturers would be melting the wax patterns and they are drained from the shell’s bottom. It is possible to recycle the liquid wax by using the water separator separation system.

It would take about 12 hours and then the liquid wax would be part of the static barrels after passing through a filter. Finally, you can preserve the wax liquid into an insulation heat box. Later, manufacturers can reuse this wax for another wax pattern.

Shell’s Final Touches

The last step in the stainless lost wax casting is roasting of the shell. After you remove the wax, roast the shell and then do the pouring. Use an oil furnace for the roasting of the shell. Give it 50 minutes in the furnace.

The objective here is to get rid of the residual wax liquid left after the wax removal. Doing so would enhance the strength as well as the shell’s permeability. This would ensure that there is no calamity in terms of shell rupture or deformation during the pouring.

To prevent the workpiece from shrinking, do remove the temperature difference between the shell and the castable liquid stainless-steel. After casting condensing, the shell needs to be destroyed and the pouring-system needs to be removed.

Everything You Need To Know About Inox Lost Wax Casting

Lost wax casting also popular as the precision casting or the investment casting is extremely effective for manufacturing complex shapes and different dimensions. You can use this technique for numerous parts and components. For instance, manufacturers greatly rely on inox lost was casting to yield better products.

You will be surprised to know that the popular metal casting process has been around for a very long time. Although, the modern lost wax casting is sophisticated and effective, however, people have been using the basic concept for ages.

Due to its numerous benefits, including integrity, repeatability, and replicating detail ability, it is the first preference for most casting manufacturers. In this blog post, we will tell you everything that you need to know about the lost wax casting process.

Lost Wax Casting: The History, and the Present

History

As we did mention above that the basic concept of lost wax casting has been around for thousands of years now. The earliest example of this particular process can be dated back to 3700 BC. Of course, they discovered this after tests with carbon 14 dating.

These initial products are discovered in southern Israel, in the cave of Treasure hoard. You can find earlier examples of this concept in many different regions and countries.

Previously, the Lost wax technique was the main method for creating both small as well as large scale casting. A 6, 000-year-old copper-amulet was found in South Asia, Pakistan. Back then, people used the lost wax casting technique to create the copper amulet.

Also, other places including Europe, Africa, Greece East Asia, Egypt, and others have found objects are were crafted using this method.

With lost wax casting, it is possible to manufacturer intricate metal components. These components are then used in a number of situations and industries. The technique can be old, but it still holds great importance in the casting industry today.

Working of the Lost Wax Casting Process

The modern lost waxing casting process is a standardized process. This means that even though every manufacturer would have its own technique to cast a certain metal. However, the basic technique would remain the same.

The process involves a number of stages ranging from wax model creation to the final finished metal piece.

See the steps below for more information.

1. The first step is to cut the aluminum tool. For this purpose, manufacturers today use 3D-CAD information.
2. Use the tools to make an original positive model. It would be a component in the wax.
3. Then the manufacturer needs to assemble the wax onto a runner system. They generally call it the assembly-tree.
4. Next comes the building of a ceramic shell. The manufacturer would use a dipping and drying process for the creation of this ceramic shell.
5. In order to provide mechanical strength, the shell first needs to be dewaxed using the high-pressure steam. And then the manufacturer fires it in the oven.
6. After pre-heating the shell, it is time to pour the molten metal into it.
7. Wait for the metal to cool, and then break the ceramic off.
8. Next coming the cutting of the parts from the tree.
9. Ingate is ground-off
10. If there is a need, the manufacturer would set, finish, and machine it.
11. Lastly, the inspection takes place. This is to ensure that the profile meets all the requirements.

When and Where to Use the Process

Manufacturers need to understand as to where and when to use the inox lost wax casting process. After all, different industries have different applications of the casting process. For example, initially and for a long-time, the jewellers along with sculptures makers and small parts makers have been using this technique.

However, technological advancement and sophisticated equipment makes the technique the most common casting method. It now holds great importance in a number of industries including the rail, automotive, mining, and the medical industry.

Even the aerospace industry greatly relies on this technique for high-quality, precise, and robust parts. It seems that almost every manufacturing methods that require complex, yet precise metal parts or components would use the low wax casting process.

Types of Metals

Another great thing about the inox lost wax casting process is its versatility. It means that the process allows manufacturers to use a wide range of products to create high-quality, robust parts.

Below are some of the common materials that most manufacturers use.

1. Aluminum Alloys
2. Copper-based Alloys
3. Cobalt and Nickel Alloys
4. Carbon Steels
5. Heat Resistant Alloys
6. Stainless-steel Alloys

Advantages of Lost-Wax Casting Method

The process offers immense design flexible and a great degree of precision. Therefore, it is an excellent choice for complex, small-size parts.

You can add Logos, Product ID, Numbers among others to the cast that you create using this method.

Investment casting does not need additional procession. For example, surface polishing, or finishing. It yields better results in comparison to all other casting techniques.

Inox lost wax casting results in products that are robust and they have a tighter tolerance than other casting processes such as the sand-casting process.

The lack of additional final finishing reduces the overall cost. Thus, making the technique cost-efficient.

The casting technique provides the exact shape, thus reducing the material cost.

It also decreases the expensive machining operations, thus resulting in a decrease of the initial tooling cost.

One of the greatest advantages of the inox lost wax casting technique is that it is environment friendly. As it is possible to reclaim and reuse the wax products that it creates.

The technique also helps enhance the performance of the parts.

 

Summary

Even though the inox lost wax casting process may seem simple on paper, but it is an extensive and highly technical process. To ensure its success, the manufacturer needs to have cast knowledge and extensive skills.

At Essaii, we provide the highest quality of low wax casting as we have the best people on board. We will be your one-stop solution for all your casting requirements.

For more information, contact us today.

High Precision CNC Machining: What Merits Does it Offers?

 

OEM engineer leaders are presented with new challenges every-day due to innovative technology and always-expanding global market. They are searching for ways to increase profit margin, satisfy their consumers, and entice consumers with uniqueness. High Precision CNC Machining is perhaps an effective way to retain a competitive edge.

In this blog post, we are going to provide you with a detailed introduction to high precision machining, its benefits, and why it is so important. So, without any further delay, let us get started!

Introduction to High Precision CNC Machining

What is High Precision Machining?

It is a process that uses raw material from an object to create finished products of a smaller size. The process involves a number of cutting machines, human engineering techniques, and software applications.

Being an extensive process that requires utmost care and complete attention. Firms that need third-party organizations for the production of their machine parts, would also rely on other companies for precision machining work.

There are many reasons for outsourcing the work, either the company is overwhelmed by all the extra work, it is a small shop that can not afford the CNC machine. There is no harm in outsourcing, however, it important to consider all your option before hiring a third-party.

CNC Machining Technology

Modern and sophisticated manufacturers prefer products and parts to meet the exact, provided dimensions. Therefore, manufacturers today rely on Computer Numerical Control machines. For instance, there are certain manufacturers who have built their own multi-axis CNC milling. They are turning these machines into their shops.

Advantages of the High Precision CNC Machining

Below, we have listed the advantages of outsourcing and using precision machining

Low Error

The chances of error are nullified when using a Precision CNC machining. All you have to do is to ensure that you enter the correct specifications. Once you key them in, the automated precision machining method takes over.

Here, the chances of error are very low especially when compare it with the human machining. Outsourcing this work would eliminate your need for higher highly skillful and experienced staff required for machine operations.

Less Material Waste

Since the main purpose of precision machining is subtraction, so it goes without saying that significantly reduces material waste. After all, there is great potential for material wastage especially in the case of human machining.

However, using precision machining would reduce the material cost. You can save additional on your material cost in you hire a professional precision machining company.

How? These companies buy material in bulk. Thus, it would cost them less and they would pass on the savings to you.

Precision CNC Machining offers consistency

With precision machining, it is possible to achieve consistency from time to time. Every product or part would be of the same quality and excellence. Even if you produce them in multiple batches, the quality of the products or parts would remain consistent.

This consistency in terms of premium quality would lead to greater customer satisfaction and increase customer leads. It would also enhance customer confidence in your brand.

Improved Workflow

Companies that allow their engineers to work on product development instead of tiny design changes are always able to manage the opportunity costs. So, when you reach out to a professional precision machining service provides, they would be making minor modifications during the prototype process.

This is to make sure that the product is according to the requirement as well as the industry standards. Since the company would be doing the tedious and meticulous work, it would leave you engineers ample time to work on product development.

Reduced Turn around Time

With Precision machining, there is no denying the turn around time reduces significantly. After all, the machine is able to perform in an effective and efficient manner than humans. So, even if you have an in-house precision machining system or you are going to hire a third party, you would witness reduced turn-around time.

However, reaching out to an experienced company would further reduce the turn around time. Since they have a running business, all the equipment and labor are in place along with immense experience. The third-party precision machining company would yield more effective and efficient results.

Production Cycles

With High Precision CNC Machining, it is possible to introduce your product at a much faster pace. This would give you the edge and the flexibility to establish your product against companies that still rely on conventional methodologies.

What more is that you will be able to update and upgrade your product as per the changing customer requirements and industry standards seamlessly.

Prototype Testing

With precision machining, it is now possible to explore the market’s smaller niche that has the potential of higher returns. As you are determining the niche opportunity, you can use the precision machine’s flexible product development phase. In case, your product has a market scope, you can effortlessly shift to a full-scale production model.

Unlike the concept prototypes, precision machining prototypes offer functionalities. They would provide you with a clear picture of how your product would feel, look, and work in the real environment.

Also, functionality prototypes attract investors' attention in a better way as compare to the only-concept prototypes.

Importance of High Precision Machining

High Precision CNC machining has evolved to become an important part of the manufacturing cycle. It offers efficiency, accuracy, and effectiveness. Precision machining has become imperative across industries.

Below are some of the industries that greatly use high precision machining.

Medical Device Industry

Orthopedic and cardiovascular devices greatly rely on the EDM and the 5-axis milling. In addition, there other implants and surgical instruments use this precision machining to produce consistently high-quality parts and components.

Medical CNC Machining

There are several factors that have a direct impact on the medical procedure’s outcome. The same rule applies to the medical CNC machining. When the equipment is able to control dust and temperature, it can guarantee high precision results. Also, it needs to ensure an ideal environment for every process along with stringent tolerance.

Surgical Scissors

These are perhaps one of the most important tools. Doctors use them in almost every medical procedure. They serve multiple purposes. For instance, doctors use them to get into the skin or to sew.

These scissors come in a wide range of sizes and shapes. Therefore, are well-equipped for different processes. For example, the surgical scissors that are required for eye surgery are extremely small. These scissors require precision and consistency in terms of quality.

Therefore, surgical manufacturers choose reliable, professional, and experienced CNC machine shop.

Cannula

Vein cannula is a popular medical product as they are in popular demand in medical centers almost in every part of the world. Like numerous surgical instruments, these products come in a wide range of sizes and shapes. They are like the needle gauge.

To manufacturer high precision casing, manufacturers need to use wire EDM or the Multi-spindle milling. As both of these are the most sophisticated CNC available.

Saws using during Orthopedic Surgery

Since orthopedic surgeon requires high precision equipment. The reason being, they have to cut into the human bones using sawing. Accurate and precise saws will help you cut as quickly as possible without going very deep.

To ensure the precision and the quality of every saw, it is important to rely on a professional high-precision CNC machining manufacturer.

Aircraft

The modern and sophisticated aircraft no longer rely on canvas biplanes and wooden wire. Their ever-expanding need for precision and complexity requires something greater and robust.

Aircraft now require consistency, durability, and sturdiness. It is not possible to overstate the complexity of today’s aircraft. They have aircraft turbines, decorative systems, sophisticated avionics, advanced engines, and hydraulic surfaces.

All these components would require advance, and high-quality components to function properly. As you build the air travel, it is imperative that the aircraft has the best components to operate safely, reliably, and efficiently.

It is not possible to deny the importance of precision machining in military aviation and civil aviation parts. In some cases, the precision machining engineers would redesign the overall application level in order to enhance its functionality.

5-axis CNC machine tool is an amazing way to ensure part accuracy and quality. It is used for aircraft components. It has a great time around time as well.

High Precision CNC Machining Jobs

In terms of jobs, the CNC machining holds great importance. Manufacturers are always looking for experience in business management, team leadership, and the following areas.

Specialists or Tool Workers

There is a wide world for people who are skilled in CNC machining tools. Some of the roles include turning impression, toolset production, having basic programming knowledge, fixture development, fixture design, among others.

Machinists

This includes several roles ranging from floor mangers to operators.

Summary

Precision CNC machining is the new way to produce high-quality, sophisticated parts while guaranteeing accuracy batch after batch. However, to ensure the smooth running of the entire project, you need to choose a professional high-precision manufacturer.

At Essaii, we offer premium quality CNC precision service. Contact us today for more information.

How to Make the Grind and Welding Process Effective and Efficient?

Despite all the technological advancement and automation, the grind and welding process is and will likely remain an intensively manual operation. When rubber comes in contact with the road, the concept is grinding. Or to be more precise it is when the grain comes in contact with the metal.

Grinding can seem to be a simple process, however, for effective results, it is imperative to pay attention to details. The process demands applying the right amount of pressure on the correct angels. Doing so will ensure the removal of most metal in a short time.

There are several variables that are effective for the smooth flow of the parts. No matter how fast and the upgraded upstream process you use, it would take a parts day if not months to get through the grinding department.

This topic is extremely extensive; however, we do present some of the most effective tips to ensure the success of your grinding operations. These factors would provide you some initial ideas.

How to Ensure the Success of Grind and Welding Process

Right Tool

Make sure that your power tools are not consumable like the grinding discs. Therefore, you need to be selective when it comes to grinders. Do go with any, in fact, choose that one that can adequately handle your job’s amperage.

For example, if the applications require 8 to 10 amps of pressure and you opt for 6 amps, right-angle grinder. We can assure you are that are in trouble from the very beginning.  As the process would move forwards, things would get worse.

Since grinder is not a tool that you would throw away, therefore, we highly recommend investing in it. Instead of choosing any random grinder, go with a fine-quality industrial level grinder. It would cost you almost double, however, you can measure its operating life in years, and not in weeks.

Both the flap discs and the grinding discs are compatible with the right-angle grinders. Combining a low-quality grinder would high-quality grinding discs would yield better results. However, it would lack the smoothness of premium quality grinders and grinding discs.

Safety Comes First

When you use the right tool for the job, it automatically ensures safe operations. For instance, using a grinder without guarding would open doors to a lot of potential injuries. Also, if the OSHA figures this, the company would have to pay a hefty fine.

Yes, we understand that the guard can be troublesome in some situations. However, without the guards, things can get serious. Things would become even worse if you are using the wrong tool or you are underpowered.

So, if you are planning to grind in the tight areas, removing your guard and squeezing in the right-angle grinder is not the way to go about it. Use the file grinder. It would be the right tool to guarantee job efficiency and accuracy.

Before you change the abrasive media, it is important to unplug the tool. When changing the media, we recommend using the power tool’s head in order to lock the key button. Put the tool on your forearm, facing upwards. Now take your time and remove the abrasive.

Performing these steps would offer more control during abrasive changeout. In addition, it won’t allow the abrasive to drop.  After all, dropped abrasive is among the commonly overlooked reason behind abrasive failure.

Also, the fall of the disc during a high-RPM right angle grinder can lead to some serious damage. You need to be extra careful as the smallest crack can make the discs lose during the operation. Too often the operators are putting back the disc after it drops out. Of course, they do inspect it first, but this is not a reliable and safe solution.

Spark Flow

Limited shops do have an ammeter at hand. It is a tool that you can use to keep a close check on the operator. It lets you determine whether the operator is pushing too hard or it is taking things lightly. It is possible to alter the change depending upon the grinding wheel and the tool.

Optimal pressure for the industrial grinding application ranges between eight to ten amps. In case, the ammeters show reading above this range, you need to slow down. However, if it shows below that range, you need to gear up.

Unfortunately, not all shops have ammeter at hand. Therefore, you need an alternative. The good news almost all applications produce sparks during the grind and welding process. Manufacturers use these sparks as an indication of the pressure. These sparks act as a visual ammeter.

Wondering how the sparks can help determine whether the process is working effectively or not? In most cases, the sparks would flow about three to four feet away from the work-place. If you find the sparks not following this particular pattern it means you are either overdoing it or underdoing it.

When you push too hard, it would overheat and overload the disc. This would result in the grains to glaze over. They would then become smooth. Since the grains are no longer cutting into the weld, therefore there would be spark reduction.

Likewise, when you are not pushing enough, you are not fully engaging in the workplace. Every disc rotation would not yield enough weld metal.

Pay heed to the Grinder Sound

The grinder’s sound is another effective way to figure out the problem. Applying the right pressure would produce a sound that has a contact pitch. In case, you are underdoing, the pitch volume would increase. In the case of overdosing, there would a drop in the volume.

The Right Working Angle of Grind and Welding Process

In general, you would have to use the grinding disc at angles that are five to ten degrees horizontal. Also, the pattern present on the disc face should be double its thickness. For example, if the pattern is 0.5” wide, the disc should be 0.25” thick.

If you have a disc thickness of 0.25”, but the wear pattern is let’s say 0.75” and your approach is flat. It means that you would the angle approach is not appropriate. It is too high, especially when several grinding disc’s grains will be engaging together.

Aluminum Extrusion manufacturer: A Step by Step Extrusion Process

 

In recent times, there has been an increased demand for Aluminium Extrusion  in product manufacturing and design. This led to an increase in the demand for a professional and reliable Aluminium Extrusion manufacturer. Technavia presented a report showing that there would be an annual growth rate of almost 4%.

In case, you are unaware of this manufacturing process, you are in the right place. In the course of this article, we will talk about Aluminium Extrusion in detail. So, without any further delay, let us get started!

A Guide on Aluminium Extrusion

What is Aluminium Extrusion?

It is a process that forces an aluminum alloy material through a die while using some specific cross-sectional profile. The manufacturer uses a powerful ram to pus the aluminum through the die. Due to the intense pressure, the aluminum comes out of the die opening.

When the aluminum comes out of the die’s front, it has the same shape as that of the die.  A runout table then pulls out the aluminum. Aluminium Extrusion is easy to understand the process, especially at the fundamental level.

You can link the force applied to push the aluminum via the die’s front as to that of squeezing a tube to get the ingredient out. The substance present inside the tube would take the same shape as the opening of the tube after you apply pressure to it.

So, it means that aluminum shape would depend upon the opening of the die. For round shape, you would require round opening, for square, square opening, and so on.

Shapes to be Extruded

You categorize the extruded shapes in three different categories.

1. Solid

Solid shapes do not have enclosed openings or voids. Angle, beam, or the rod are common examples that fall under this particular category.

2.  Hollow

Hallow usually comes with one or more voids. For instance, a rectangular tube or a square tube.

3.  Semi-hallow

These shapes generally have a void that is partially enclosed. For example, the “C” channel having a narrow gap.

Extrusion is popular among numerous industries including the energy, aerospace, electronics, automotive, architecture, and several other industries. You can achieve even extremely complex shapes by using multiple extrusion processes.

The Aluminium Extrusion Process

Below, we have explained the Aluminium Extrusion process in ten steps.

Step 1: Preparing and Moving the Extrusion Die

For starters, an Aluminium Extrusion manufacturer would use H13 steel for the machining a round-shape die. Of course, some manufacturers would already have the desired shape. In that case, they would simply pull it out from their warehouse.

The die needs to be preheated between 450 to 500 degrees Celsius. This would not only help maximize the lifespan of the die but at the same it, it would make sure that the metal flows evenly. Once you preheat the die, you can load it into the extrusion press.

Step 2: Heating Aluminum Billet Before Extrusion

The next step is heating the aluminum billet. It is basically a cylindrical solid block of aluminum alloy. Manufacturers extract the billet form a longer log of aluminum alloy material. You should have to preheat this in an oven. The temperature needs to be between 400 to 500 degrees Celsius.

Heating the billet would not melt it completely. However, it would make it malleable enough to yield to the extrusion process.

Step 3: Transferring Extrusion to the Billet Press

Once you heat the billet as required, it would mechanically be transferred to the extrusion press. However, applying a release agent or a lubricant onto the billet is important. This step needs to take place before the loading of the billet into the press.

Also, it is important to apply the same release agent to the extrusion ram. Doing so would ensure that the ram and the billet do not stick together.

Step 4: Pushing the Billet in the Container

After transferring the billet to the extrusion press, it is time for the apply the pressure. The ram would apply around 15,000 tons of pressure to the malleable billet. The application of the pressure forces the billet into the extrusion press’ container.

The material than would expand and gradually fill the container walls.

Step 5: Extruded Material Coming Out of the Die

Even after the material fills the container, the ram is still applying pressure. It means that now the material is pushed against the extrusion die. Due to continuous pressure, the aluminum material would go through the die’s opening.

When it comes out from the opening of the die, it is in the exact shape as that of the die opening. This means, that you have achieved your desired shape so far.

Step 6: Quenching and Runout Table

When the extrusion comes out from the die’s front, a puller holds onto it. This puller is then responsible for guiding it along with the run-out table. The speed of the table would match the speed at which the extrusion is coming out of the press.

With the run-out table movement, the profile is quenched. To ensure its sturdiness, it needs to be cooled uniformly. Aluminium Extrusion manufacturer either uses fans located above the table or they rely on water baths.

Step 7: Extrusion Shearing

After the extrusion has reached its full table length, it is not time to sheared it away from the extrusion process. For this particular purpose, manufacturers use a hot saw. The saw would separate the particular extrusion from the extrusion process.

NOTE: Temperature is an extremely important aspect of the extrusion process. You need to keep a close check on it at every stage of the extrusion process.

Even though you quench the extrusion after it leaves the press, it still requires time to fully cool down.

Step 8: Extrusion Cooling at Room Temperature

After the shearing takes place, it is time to transfer the extrusion from the run-out table to the cooling table. This process would take place mechanically. Now the manufacturer would wait for the profile to reach room temperature before shifting it to some other place.

After they cool down, it is important to let them stretch.

Step 9: Moving Extrusion to Stretcher

Sometimes, there is a certain twisting that occurs in the profile. As a professional Aluminium Extrusion manufacturer, you would have to work on it. In order to correct the problem, you move the table length extrusion on to a stretcher.

Every profile is gripped from both sides. It would mechanically be pulled until it reaches the desired specifications.

Step 10: Sawed According to Specifications  

Now that the table length extrusions are fully cooled and they are straight as well, it is time to transfer them to the saw table.

Here, these extrusions are sawed according to the length. In general, the length ranges from eight to twenty-one feet.

NOTE: The properties of extrusion at this particular stage are similar to that of the T4 temper. After sawing, it is possible to age the extrusion to T5 or T6. In order to do so, you would have to move them to an aging oven.

 

The Final Touches

After the completion of extrusion, it is possible to enhance the properties of the profiles by giving them heat treatments. To enhance the finished look of the extrusions, Aluminium Extrusion manufacturer uses different finish types.

However, these finishes need to be done the heat treatments. To bring the extrusion to their final dimensions, they need to go through different fabrication operations.

Improving Mechanical Properties

It is possible to enhance the tensile strength and stress taking ability of alloys in the 7000, 6000, and 2000 series. In order to get these enhancements, it is important to put the profiles into ovens. These heating treatments would bring the alloys to T5 or the T6 tempers.

Surface Enhancement

There are numerous finishing operations that aluminum profiles would undergo. Surface enhancements not only improve the overall appearance of the aluminum but at the same time, it also improves it corrosion properties.

For instance, when you anodize the aluminum, it would result in the natural occurrence of the oxide layer. Thus, resulting in the thickening of the metal. Also, the process would enhance the corrosion resistance of the profile. In addition, the metal would become more resistant to wear.

Likewise, it would result in a porous surface, it means that the surface would accept different colors. The surface emissivity would be enhanced as well.

There are some other finishing processes available as well. Some of them are listed below:

1. Sandblasting
2. Powder Coating
3. Painting
4. Sublimation

Summary

Aluminium Extrusion is a process that manufacturers use to create components and parts having certain cross-sectional profiles. To enhance both the properties and appearance of the aluminum, the manufacturer uses different mechanical and surface enhancement processes.

The Aluminium Extrusion manufacturer also uses certain fabrication process to acquire the final dimensions of the product. After all, their objective is to achieve high-quality aluminum parts.

In case, you are looking for an Aluminium Extrusion supplier or manufacturer, you can reach out to us. We will provide you with all that you are looking for.

Factors that Contribute Towards the Cost of Custom Aluminum Extrusion

If you think that custom aluminum extrusion is not affordable, you have been interacting with the wrong kind of manufacturers. You need proper planning to get custom extrusion not only on time but also within budget.

Despite steel being the common choice across industries, aluminum is becoming popular with the passing time. After all, it has a lot more to offer. It ensures corrosions resistance, durability, strength, weight, numerous finishing options and low maintenance.

What more is that with aluminum, architects and product designers are able to acquire destinations that might seem like a dream in case of steel. Aluminum contributes significantly to the sustainability efforts, after all, it is among the most recycled materials in the industry.

Aluminum Extrusion: Important Elements

Funding and feasibility are the two major factors that govern the custom aluminum extrusion. These after all a matter of the circle size along with the required weight of the shape per linear foot. Although, the combination sounds extremely complicated.

However, we can assure you that it is fairly easy to grasp. In simple terms, it is the ratio between the profile size and the thickness of the material. Sine the extrusion presses different in terms of their capability, finding the one that suits you best is the matter of looking around.

For instance, if you have a profile that has a section area ranging between 1 to 2.5 square inches and it has a diameter that is 1 to 10. Finding an aluminum extruder for this particular profile would not be a challenging task. Since it lacks complexity, most extruders would be able to do a good job.

On the contrary, if you want a profile that requires a circumscribed circle greater than 14 inches, dia and the cross section is greater than 10 square inches. This is something challenging and only experienced extruder such as the Essaii would be able to handle it with perfection.

Cost Factors

Die is the major contributor to the cost of the extrusion process. You would likely have to pay for 1000 of dollars for the die. However, this cost is not significant when compared to the entire architectural project.

In addition, in most cases, the lead times are usually less than a month. So, these factors would contribute the custom extruding’s affordability. For example, the revisions required, or the full-scale prototyping.

Other factors adding to the project cost include the custom-made check-fixtures along with the tools that are required for the bending machine.  In order to cut down the overall custom extrusion expense, you should consult an experienced and relevant extruder.

Design Guidelines

Even though the extruded shapes have some limitations, yet they do offer design freedom and substantial versatility. Since custom aluminum extrusion is creating a new profile form the scratch instead of purchasing off-the-shelf profile, therefore you have different options.

It is up to you to choose the dimensions, shape, structure and other aspects of the aluminum profile. Below is a basic table for guide design.

Alloy Selection

When it comes to alloy selection, aluminum offers a wide variety of tempers and alloys. For instance, for the construction and building applications, manufacturers would recoomend the 6XXX series. Even though some other alloys may offer greater strength.

However, 6XXX series is excellent for electrical conductivity. It has the best combination of properties for the construction business. Alloys to consider are 6005A, 6061, 6063, and 6060.

Profile Design

When you reach out to an experienced custom aluminum extrusion manufacturer, you would get read input on the profile design. Reaching out to an extruder is imperative if you are new to extrusion. You will be surprised to know that small differences in the design can lead to significant reduction in terms of cost.

For starters, you need to think out of the box. We agree that I, C, L and rectangle work well for several application, but then you don’t need custom aluminum extrusion. You will be able to find most of these shapes right off-the-shelf.

Next, it is important to keep the design simple to ensure the success of execution while keeping a firm hold onto the cost. See some effective tips below.

1. Use gentle radii and corners.
2. Keep tongues as shallow and as wide as possible
3. Ensure uniform thickness of the walls.
4. Design while having symmetry in your mind.

When we say unique, we don’t mean complex. By unique, we mean a design that serves the purpose while being eye-catching and bold.

Surface Specifications and Tolerances

You easily find the industry-standard tolerances online. However, a good and reliable custom aluminum extrusion manufacturer would ensure tolerance higher than the industry standards. After all, they plan to delivery only the best.

So, a good way to go about this is to talk to your extruder. They would be able to provide you with the required information as well as how the acquiring the standards would impact your overall cost. At this stage, you should also discuss the project visibility as well as the surfaces that are associated with these particular areas.

Structural Considerations

There is no denying that creating optimal structure is more than one-time cycle. It is an iterative process that starts with the functions. It then moves through a number of forms, joining methods and geometry considerations.

For start, you should consult the aluminum design manual. It consists of the aluminum basis for the construction as per the international building standards along with aluminum structures specifications.

Custom Aluminum Extrusion offers Different Finishing

Once you extrude, the aluminum promptly creates a tenacious oxide film. The purpose of this film is to provide additional protection against corrosion. In most cases, you won’t require additional finishing.

However, if you want to enhance the physical appearance or sever service conditions, you would need additional finishing. Do bear in mind that the additional finishing would increase the cost. So, do these finishing only when they are a must.

To further know how this finishing would impact your project cost, you should talk to your extruder. They are the best source to acquire authentic and reliable information.

A Brief Introduction to Investment Casting

Over the years, the investment casting process has evolved to a great extent. A modern dewaxing casting manufacturer can create extremely complex and complicated parts with disrupting the shell or the mold. Since the process is vital, therefore, you need to have its basic understanding.

In the course of this article, we are going to present to you a brief introduction to the investment casting process. We will explain its manufacturing along with applications. So, without any further delay, let us get started!

Process of Investment Casting

With investment casting, manufacturers are able to achieve highly detailed, complex, and accurate metal castings. The basic idea of investment casting comes from the ancient concept of the lost wax method. Since it offers a number of benefits, therefore, it is an important technique to create a number of equipment and parts.

History

There is no denying the importance of the investment casting process. You will be surprised to know that the lost wax process has been around since 4000 BC. The origin of the concepts is believed to be in the Middle East, North Africa, and Asia.

Initially, the concept was used to design and develop beautiful, complex sculptures and jewelry. In old times, the manufacturers relied on the bee’s wax. However, today, they are able to use any material that has a similar composition as that of the wax.

Heating and softening of the wax led to the creation of the desired shape. This basic concept has remained the same through the modernization and evolving process of the investment casting technique. The dewaxing casting manufacturer today use industrial molding compounds.

Modern Times

In the early 20th century, the wax casting process was popular for creating equipment for the dental industry. However, due to WWII, there was an increase in demand for almost ready parts. Numerous industries including the military were searching for ready parts in mass volume.

Thus, the casting process becomes popular and effective. Currently, manufacturers demand highly sophisticated parts and components. To achieve the required level of sophistication, they would have to rely on investment casting. The lost-wax method influences almost everyone’s life in one way or the other.

Investment Casting Process

Step One

The first step involves the injection and assembling of the wax patterns. The manufacturer would inject the pattern onto a wax tree, or the gating system and the runner. In order to ensure smooth casting and dewaxing, the system incorporates a ceramic pour cup.

The cup is extremely useful in assisting both, dewax & casting processes. Usually, the soluble wax cores are present in the complex patterns. However, it is important to remove these cores before you start with the shelling and the assembling process.

In case, you require air or cavity passage in the final product, then you should use the core. It would yield the desired results.

Step Two

After you have assembled the wax patterns onto the runner and the gating system or the tree, you need to look for the minor imperfections. To do so, you check and dress the assembly of the gating system.

Remember, you need to pay extra attention to this particular step. After all, the flaw that goes unnoticed in this step is going to be part of the finished metal components. Something that you need to avoid as a manufacturer.

To provide the optimum wax substrate, most manufacturers recommend that you dip the assembly into the triol pattern etching and wash agent. Complete this step before heading onto the shelling process.

Step Three

Now it is time to apply a series of ceramic coating around the wax assembly. Doing this would result in the formation of the shell around the wax assembly. You would have to slowly increase the particle size. To be more specific, manufacturers first dip the wax assembly into a liquid slurry solution.

After that, they apply refractory stucco materials to it. Both of these things combine to make the required shell coating. Give some time to the shell material to set and then head towards the dewaxing process.

Step Four

It is time to remove the wax from the shell system. In most cases, the manufacturer relies on the steam in the autoclave dewax process. Some of them even use high temperatures, especially for the dewax flashfire method.

Regardless of the type of process you use, the left-out wax is collected and recycled. Now it is time to condition the shell and high temperature and fire it. This would lead to the manufacturing of precision casting moulds.

These moulds are ready for part creation. They now have the strength and the sturdiness to accommodate molten metal.

Step Five

To get rid of impurities as well as to enhance molten metal flow manufacturers add ceramic foam filters. These filters also add precision to the mould casting process. Next comes the cooling rates. In order to control these rates, there is a covering of fiber insulating blankets around the mould.

Once the moulds have the insulating covering, they will be introduced to the molten metal. Several techniques are available for the introduction process. For instance, the conventional hand pouring method or crystal-casting technology.

The type of technique used greatly depends upon the complexity of the part or the component. For instance, for highly complex alloys, we recommend using the single crystal-casting technique. However, in the case of lesser complicated parts, you can go with the orthodox hand-pouring method.

Step Six

Give ample time for the alloys and metal parts to cool down. After the cooling down process, you would need to remove the shell material via mechanical processes. In case, there are some internal ceramic cores left, you can remove them casting through a dissolving method.

You would have to dissolve the casting into a caustic solution and yield the desired results.

Step Seven

Lastly, it is time to remove the casting from the tree. The manufacturers would thoroughly inspect the finished product. They would even recycle the reaming material present in the gating system and the runner.

Do bear in mind that to yield effective results, the process requires complete attention and precision. You would have to control the process at every stage to ensure an accurate and error-free product. Only then will the product have the required mechanical characteristics and dimensions.

Importance of Dewaxing Casting

Dewaxing casting holds great importance in the investment casting process. You need to have proper knowledge as it can define the quality and composition of the mold.  There are many aspects of the de-waxing casting technique.

In the course of this article, we going to talk about the dewaxing of the shell. So, without any further delay, let us get started!

Introduction to Dewaxing Casting

To ensure the quality of investment cast mould, it is imperative to pay close heed to the wax removing process. After all, it is among the most important step of the cost mould. Dewax can lead to a number of problems.

For instance, it can cause microcracks. After all, the de-waxed or the green shells are fragile and vulnerable before firing. To hold the components of the shells together, manufacturers either use fibers and polymers or colloidal networks.

In most cases, the manufacturers depend upon the autoclaving method for removing wax patterns. However, there are certain manufacturers that de-wax via the flash firing method. The choice greatly depends upon the manufacturer’s preferences and requirements.

The major benefit of using steams instead of the air in the baking oven is to ensure effective and efficient energy transfer to the interface layer of wax. Moreover, the autoclaving methods permit the reclamation of the melted wax.

It also reduces the release of contaminating gas especially when you compare it with the flash firing method. There is little to no amount of wax left behind after the completion of the autoclave dewaxing process. This then results in less production of ash during the firing procedure.

Autoclaving Method

For an instant heat source, the autoclaving procedure uses steam. The steam is familiarized with the shell surface. The constant introduction of the steam leads to a change of state in the solid wax present in the shell.

The wax starts to melt and at the same time, there is increased stress on the shell’s inside surface. The stress is the result of the liquid volume expansion and the phase transformation.

NOTE: It is vital to release the pressure build inside the shell due to expansion as soon as possible. Lack of pressure release would lead to the cracks in the shell.

Release Mechanism

The pressure release mechanism is simple and effective. What happens is that after the steam penetrating the shell melts the solid wax inside, the melted wax then passes into the prime coat. To enter the prime coat, the wax penetrates the shell.

The decrease in the shell stress is due to the penetration of the liquid wax into the prime coat. Likewise, the polymer present in the shell makes it robust and strong. It offers a better system for absorbing the pressure that is building up in the shell.

Prime Coat- Shell Properties

Manufacturers greatly emphasize the fact that relieving the right amount of pressure via the prime is important. However, it is important to understand that the pressure relieve should not compensate for the integrity of the prime coat nor should it have an adverse impact on the surface roughness.

To increase the shell's ability to withstand pressure, manufacturers something incorporate polymers into the prime slurry. The polymers also help absorb the wax expansion. Thus, making the shell sturdy and strong.

It is important to wet the prime coat using the liquid wax as this would ensure better shell permeability. There are several factors that influence surface wetting. For instance, the temperature, surface heterogeneity, roughness of the prime coat surface, wax liquid characteristics, and the rate of wetting.

Backup Coat- Shell Properties

In order to avoid all sorts of shell cracking, you need to pay extra attention to back up coats. After all, these coats need additional strength for the penetration of the shell cracking. The number of back up coats greatly depends upon the mechanical strength and the slurry system.

You can have as little as four backup coats or the number can go up to 12 or so. Do bear in mind that the shell thickness would lead to an increase in the heat capacity of the shell. Thicker the shell, higher its heat capacity.

Also, higher thickness requires additional steam energy to convert the solid wax within into liquid wax. Thus, you need to have a balance of the permeable shell system. Prevent the right amount of steam penetration along with good mechanical strength.

To further enhance the stability and the survivability rate, it is a good idea to add polymers to the shells.

Dewaxing Casting Properties

For the making of investment casting-pattern waxes, manufactures mainly use the microcrystalline waxes and the paraffin waxes as the base wax. They then add plasticizer, fillers, and resin. However, the decision of adding plasticizer, resin, and fillers depends upon the application type.

Each factor offers different benefits. Like, adding fillers to the wax would reduce shrinkage, it would enhance dimensional performance and result in better mechanical properties.

For the designing of wax good for autoclaving dewaxing casting, there are different parameters that hold importance. For instance, you would have to focus on the conductivity, heat capacity, melting point, viscosity, and thermal expansion.

Autoclave Dewaxing Suggestions

In most cases, the manufacturers suggest running auto-clave at least six bars in three seconds. Then allow the pressure to recover up to eight or nine bars. Do bear in mind that there should be a steady increase in the steam pressure along with the simple pressure.

Higher depressurization rate would have an adverse impact on the mold’s pressure pockets as well as the case of the condensed steam. This would then be leading to the cracking of the mold.

Also, to ensure the effectiveness and efficiency of the mold, we do recommend that you run a couple of dummy cycles. This would provide you with the idea of the outcome. It is important to incorporate seal inspection, regular maintenance, safety systems, and door operation in your daily inspection routine. However, this setting does differ from manufacturer to manufacturer.

In case you are looking for more information on dewaxing casting, reach out to us today. We will provide you with all the information that you require.

What would influence the dewaxing casting manufacturer’s selection?

Modern parts and components have become complex and sophisticated, therefore, choosing the right dewaxing casting manufacturer are imperative. Only a reliable and experienced manufacturer would be able to yield effective and efficient results.

What you need to understand here is that the process of choosing a casting manufacturer or supplier is not the same as choosing a supplier for your office accessories, manufacturing equipment, or the bolts. Even though some consider metal casting as a commodity, but the truth is the opposite.

Metal casting is far from being a commodity, therefore, you need to conduct careful consideration. After all, the quality and robustness of your parts and components depend on this particular decision.

Dewaxing Casting Manufacturer’s Selection

In the purchasing process, we firmly believe is the importance of the supplier qualification. Initially, the purchaser’s main duty was to find a responsive and qualified supplier. Therefore, in most cases, suppliers that were meeting the basic requirements of the purchase were qualified.

However, with time and experience, it was understood that the quality purchasers need to focus on the quality of the product as well. Low-quality products would lead to a number of problems. For instance, it would result in product failure, loss of money, and wasted time.

These are things that you cannot afford in the modern business world. Therefore, you need to make the right decision the first time. To make things easier for you, we have come up with a list of things that you should consider.

Market Experience

This goes without saying, when choosing a dewaxing casting manufacturer, you need to focus on their experience in the respective market. Doing so will help you choose the right foundry to do business with.

After all, a metal casting manufacturer with experience would understand your applications, products, pain points, and terminology. They would be able to anticipate the requirements and potential problems. This is highly important especially when you want products and components for nuclear, defense, aerospace, and similar compliance markets.

Fortunately, you will find the key markets of most casting manufacturers on their website. Thus, making it extremely easy for you to short-list the supplier.

Dewaxing Casting manufacturer focuses on Process Diversity

Several casting manufacturers are limited to only one type of casting process. Of course, they would sell you exactly that process claiming it to be universal. For instance, if the sand-casting technique works well for your product. However, the manufacturer that you are planning to invest with offers only investment casting?

What are you doing? Going with investment casting would not be a wise decision. Therefore, opt for suppliers that would offer diversity in terms of the casting process. This would allow you to choose the right kind of casting process for yourself.

In case, your components have a range of applications, designs, and sizes. It is highly less likely that the same casting process would work well for all the parts. In case, you want to choose a single course for all your casting requirements, make sure that the manufacturers offer diversity in terms of its capabilities.

Product Price, Service, and Quality

When choosing the right casting manufacturer, you need to focus on three main factors:

• Price
• Service
• Quality

To determine the importance of every factor, take an internal audit. Do bear in mind that most companies would excel in one particular aspect, while they can accept in other areas. For example, if you have on a tight budget and want the lowest price possible, you would have to compromise on quality.

You simply can’t have the lowest price products with high quality. So, figure out your “Must Haves”. It may be Quick response, lowest price, highest quality, great specs, etc.

Testing and Certifications

An experienced and skilled dewaxing casting manufacturer would have proper certification including PED, Nadcap, ASME. The important thing to understand here is that you need to ask for a certification as per your application requirement.

If your product requires some certain certification, you need to ensure that the potential suppliers have valid and proper certs. Since most of the suppliers would list all their certification onto their website, you need to be diligent in your search. It is possible to search for a website by the certification.

Test

The next thing that you need to focus on is the type of testing process the dewaxing casting manufacturer offers. This greatly depends upon your requirement. For instance, does your product require mechanical testing, non-destructive testing, or the chemical testing.

Of course, it possible for the casting manufacturers to outsource all sorts of testing. However, certain manufacturers have in-house testing ability. This would save time and money. In case, your product does not require testing. Then choosing a manufacturer that specializes in high compliance work having the in-house facilities is not the best choice for you.

Machining Capabilities

A safe option is to go with manufacturers that have their own machining capabilities. The reason being, it helps avid conflicts that you might discover during machining. So, when there is a third party for machining, no one would take the blame. Everyone would be pointing fingers to each other.

It would be difficult to figure out whether it is the machining issue or the casting issue. So, when a manufacturer discovers an error during the machining process, they would be able to find solutions effectively and without delay.

Moreover, less time is required for shipping, processing, replacing, and handling of the products. Every phase from manufacturing to delivery would be completed efficiently. Even without problems, integrated machining would make the supply chain simple and efficient.

It would reduce the shipping cost along with the handling time before the application reaches the end-customers.

Valued Added Services

What exactly is that you want the casting manufacturer to provide you? Is it just the metal parts or components that you need from their end or you are looking for something more! For instance, if you lack the in-house metallurgy expertise.

Reach out to the supplier and ask them to provide you with guidance, provided the manufacturer offers such services. If they do, they will be able to guide in a proper manner regarding the alloys that would suit your applications.

Likewise, you can check with the manufacturer if there is a need of upgrading your company’s metal expertise via information sharing and training. Are you looking for manufacturers that can review your material and design selection? Do you want their input to ensure the longevity and robustness of your product?

These are important questions that require answers. There are some casting manufacturers who would provide high-quality products to spec; however, they lack other capabilities. Others would help you save money and time by exceeding the letter of PO.

Do you have any specific requirements for a non-ferrous or ferrous alloy? Ensure that the manufacturer specializes in all that you are looking for. They need to meet your alloys and material demands to eradicate the need for multiple manufacturers.

Tour Their Facility of Potential Dewaxing Casting Manufacturers

A Plant Tour is the perfect way to determine the facility and capability of a dewaxing casting manufacturer. You would gain firsthand knowledge regarding their work environment, strengths, and weakness. Most manufacturers would be more than willing to allow you the tour of their facility in order to acquire new business.

However, if you are not fully satisfied with their capabilities, operations, or the culture, they are not the right suppliers for you then. You need to look for other options.

Important Question

To ensure that you make the right decision, below is a list of questions that you need to ask yourself. Finding answers to these questions will help you make the right decision.

1. Does your manufacturer have experience in your applications or markets?
2. Is it possible for the supplier to limit the number of vendors by fulfilling all your product requirements?
3. What is on top of your list? Is it quality? Customer Service? Price? Or you are in search of other facilities?
4. Focus on how the strength of the manufacturer benefits your product or parts?
5. Does the manufacturer have a certification that you need for your application?
6. Does the manufacturer provide a proper testing facility? Do they outsource the testing phase or they have in-house testing capabilities?
7. What sort of value-added services are you looking for?
8. Does the manufacturer provide all the value-added services that you need?
9. Is the manufacturer familiar with the alloys you require? Do they have experience in dealing with the required alloys?
10. Does the company have a bright future?
11. Does the company have a strong history?
12. What sort of values do they incorporate? Do these values align with yours? This is imperative especially if you are looking for a long-terms dewaxing casting manufacturer.
13. Is it possible to build a relationship with the manufacturer?
14. Do you see your firm conducting business with the supplier?

Take Away

Metal casting holds great importance. Therefore, you need to find the right kind of supplier. Following the above tips would help you make the choice a manufacturer that offers quality, and efficiency. The manufacturer would be able to meet all your demands and requirement for the application.