Wednesday, 23 August 2017

7 Quick Tips Regarding Alloy Casting

Alloy means combination of metals or metals with other substance, which have metallic bonding. This alloys are used in numerous applications. Because of the combination, sometimes it’ll reduces overall costing of product, sometimes it’ll increase the overall strength, also improves erosion resistance.

For example, aluminium [soft metal] can be improved by alloying one more soft metal copper. Both metals are soft but resulting aluminium alloy have extreme strength. Steel is also an alloy, it’s a combination of nonmetallic carbon and iron. So, as per individual casting and requirements manufacturer select suitable combination of metals [Alloys]

Numerous types of alloys are used in various application as well as product. Some of the popular alloys are

  • Aluminium Alloy
  • Chromium Alloy
  • Cobalt Alloy
  • Copper Alloy
  • Iron Alloy
  • Nickel Alloy
  • Titanium Alloy
  • Zinc Alloy

Latest technologies as well as various techniques are implemented for manufacturing casting parts. At the same time proper rules and tips should be followed to build excellent parts. Let’s look at the tips regarding alloy casting as well as perfect casting parts.
  1. Analyze shape & size of parts: Accurately analyze the shape, its detailing like edges and angles, dimension etc. If any fault found in creation of mold, design or initial phase it may build defective casting part. Spend some time in designing to manufacture excellent and exact parts. Before manufacturing heat mold and talcum in advance.
  2. Select proper alloy or metals: Based on the application and requirement select proper alloy or metals. Accurately create mixture of metals to get exceptional product range. Improper alloy makes faulty or weak casting components.
  3. Determine pattern placement: Whenever create a mold, it’s important to successfully casting pattern. Always place pattern carefully without any damage or crack. If possible try to use ring for exact result.
  4. Pouring the metal: To melt dry metals always try to use electric hob, before pouring the metal perfectly melt the metals without dust. After that pour gently into the mold without damaging other parts of mold.
  5. Venting & Cutting: In this phase most of the time manufacturer makes mistake, whenever venting the mold always use sharp blade as well as give suitable heat to mold. It makes easy to cutting and removing from the mold. At least take 5-10 minutes time before open the mold.
  6. Filling: While fillings the parts, try to use a flat file in balanced form. For seam lines needle files are suitable. Carefully do the detailing tasks with small files without damaging parts.
  7. Gluing the parts: Before join two parts, always polish it and verify it by joining. It should be join without any space. Remove rough areas by polishing properly. Then apply glue or soldering to join two related parts.

Each casting required deep analysis, proper choice of alloy as well as careful procedure to produce exact and satisfactory casting parts. Hope these tips helps you to manufacture excellent alloy casting parts without any fault or error. Let’s see your ideas and views in comments.

Thursday, 10 August 2017

All You Need To Know About Camlock Fittings

Camlock fittings is an industrial parts, which is mainly used to join or dis-join two pipe or hose. Manufacturer precisely maintain its size as well as standard quality because main functionality is to connect two pipe or fill the gap of two individual functions. if you miss to learn about important rules of investment casting then take quick look before go further.

Camlock sometime also called as cam coupling or groove coupling, which is available in different materials, size, shape and categories in the market. The coupling is compulsory in liquid, gas and power industry. Other than these industries, Agriculture, Military, Drum filling etc. are uses camlock in various ways.

While manufacturing camlock fittings, some of the major parameters have to take into consideration like method, materials, dimensions, tolerances, pressure, and inspections. If you accurately deals with major parameters then it increase quality of end products.

Why Camlock:

As we know to join any two pipe easily coupling or fittings finest way. It’s frequently used in petroleum, chemicals, and water delivering only because of easy operate & installation. The design of fittings are very simple, consist of adapter, coupler and assembly of line. Primary components are male adapter and female coupler, they make strong and accurate connection.

While installing camlock no extra tool or components are required, only hand pressure is enough, which reduces your time as well as manpower. Camlock fittings aremanufactured by distinct materials like aluminum, brass, steel, polypropylene, etc. to satisfy basic requirements.

  • Aluminum: Mainly used in slurry, water and petroleum industry, because it’s economical and lightweight material.
  • Polypropylene: Mainly used in agriculture and industrial application. 
  • Stainless Steel: Especially used in sanitary & food field, they are bit expensive but having longer life.
  • Glass fiber reinforced nylon: They are applicable in low pressure working machinery.
  • Brass: Well-suited with hydraulic oils, gasoline, water, coolants, and petroleum products, having great erosion resistance.

Now let’s take a quick look about the various types of camlock coupling which are given below,

Type A: [Male end & Female Pipe Thread                                                        Type B: [Female end & Male Pipe Thread]
Type C: [Female end & Male Hose Tail]                                                            Type D: [Female end & Female Pipe Thread]
Type E: [Male end & Male Hose Tail]                                                                 Type F: [Male end & Male Pipe thread]
Type DC: [Female end camlock]                                                                          Type DP: [Male end camlock]

Advantages of the coupling are easy installation, increase productivity & reduces manpower work. 
While main disadvantage is inapplicable in acid and flammable liquid transfer.

Last words, lets quick look about what we’ve learnt, first is about camlock couplings, then why it’s important after that various materials camlock couplings with type and last advantage and disadvantages. Hope this will help you to understand all about the camlock couplings. Share your ideas and views regarding couplings in comments.

Friday, 21 July 2017

7 Easy Rules of Investment Casting

In the Investment casting, investment term refer as ceramic materials which is used as hollow part in that liquefied metal is poured to build casting components. This complete process is referred as investment casting process, many industry follows and preferred this process to build various casting components. Take a quick look for Casting Types and Process. 

In the complete process designing is the most important part, exact replica of the component is design as molded form. In that form metal is poured and get shape of desired component. Before we start discuss about 7 rules, let’s get brief information about the complete investment casting process Investment Casting – Process & Benefits.

Investment casting process is very efficient as well as economical as compare to other. It’s special investment area in which many industrial folks are interested. Following are easy and important rules should be followed by investment casting manufacturer.

  1. Process & Technology: Before start any process do some research about the manufacturing component/parts. Analyze easy and difficult parts of complete process, start with manufacturing of difficult parts and merge with easy parts for quick outcomes. Whether its sand casting, die casting, lost wax casting or through latest technology, choose appropriate method which precisely build your component.
  2. Material or Metal: Based on the application, you have to select desired material or metal which is durable as well as corrosion resistance. If you select poor material then it may produce various faults in manufactured component. Based on the requirements select metals or their alloys such as stainless steel, aluminum, copper, nickel or cobalt etc.

  3. Design: It is most important to understand investment casting design and production, without fail maintain the tolerance ratio. The linear tolerance ratio is 
    Up to .250” --> +- .004" per inch
    .251” and more --> +- .005" per inch.

    Above given values are primary or thumb rule, it may vary as per application and procedure.

  4. Strength & Weight: many time upper limit of the metal has taken as weight of the casting part, you can produce 150lb weighting parts but try to not exceed 100lb. For larger casting parts wax injection is required.

  5. Combine Parts: Many manufacturer might thinking combining parts are difficult for design as well as manufacture. But it’s quite easy to combine multiple parts into single unit and producing one balanced component, it also reduces many assembly operations. For example hooks, tubes, handles, chambers etc. are combine for one operation. Try to combine separate parts in single manufacturing which surely improves item’s utility.

  6. Edge & Corner Radii: Outside corners and edges should be design accurately, otherwise in unmolding phase it’ll break sharp edges or corner and may damage your accurate design. In the standard investment casting process 015R corner & edges radii are allowable. Because sometimes in round corner double cut of wax mold applied. Always maintain the corner and edges to reduce damage cost.

  7. Inspection Method: There are many methods to test and evaluate effectiveness of casting components. Some of the popular tests are magnetic particle inspection, radiography, as well as other destructive testing. Always be careful while evaluate or examine casting parts, sometime over evaluation may damage the precise component. Different material has different evaluation criteria in mechanical property plus chemical examine.
The last words, investment casting process is highly popular and should be follow accurately to design and manufacture industry related components. These seven rules may help you to produce precise casting components without any flaws and errors.

Waiting for your ideas and views in comments…!!!

Friday, 26 May 2017

The Seven Secrets You Will Never Know About Investment Castings Manufacturing Process

Investment casting is a complex and trendy manufacturing process. To build robust and high dimension metal parts, investment casting is prime technique preferred by every manufacture. It’s a traditional technique which also known for lost wax casting, in which mold is designed as per desired shape in that ferrous or nonferrous material is injected. All the manufacture followed same technique with the only difference of raw material and designs.

Investment Castings
  • Incapacity Dimensional: 1″ to 24″
  • Tolerance: .003″
  • Lbs. per casting: Ounces to 75 lbs.
  • Volume Capacity: 300 to 100,000
In the digital market and innovation trend, investment casting is also improves its techniques as well as exclusive technology to build more precise and stronger casting products. Energy Technocast famous for manufacture detailed and standard quality casting products with the help of exclusive techniques at the best price in India.

The most important factor in manufacturing casting parts is accurate dimension as well as reliability, analyze and test components continuously to achieve perfect dimensional accuracy as well as customer satisfaction.

If you still follow traditional procedure then surely you will faces some of the hazards like over timing outcomes, wastage of materials, inaccuracy in dimension, etc. that’s why it’s compulsory to stay advanced and apply new technology in manufacturing process to stay ahead in competitor marketplace.

Latest technologies are more flexible and comfortable in nature which makes manufacturer to build flawless casting components in short duration of time. Some of the important tricks and techniques are given below that surely helps you to improve manufacturing process.

Secrets of Investment Castings Manufactures

  • New improvement and innovation applied in process such as lost foam casting instead of manual wax.
  • Computer-based visualization tools for die casters to produce 100% accurate dimension of components
  • Increasing in manufacturing rate of components.
  • Mixture and alloy of different metals are used to build more robust and reliable components, which are high in demands now days.
  • Computerized designing gives flexibility along with high detailing
  • Reduces the time of manufacturing i.e. lower the range of hours.
  • Oxygen tanks are the trend of new investment casting manufacturing, because it’ll run out quickly round about 20 min. of usage.

Last words, it’s necessary to follow modern technology and procedure and sustain in the high competition marketplace. Hope these modern trends will help you to manufacture superior quality casting component. Waiting for your ideas and views in comments.

Tuesday, 18 April 2017

What is casting ? Different type and process of casting

In the mechanical industry casting is a process to develop or build different parts which has various shape and size along with perfect finishing. The products which are built through this process are known as casting products. In the casting process mold is created as per desired shape and pattern in which metal is poured and after the cooling phase it become exact or desired casting parts.

Casting process is a traditional process it has been known from thousands of years, and most popular method to develop small and accurate casting parts. There are mainly three procedures to develop casting parts such as Expendable Mold, Non-Expendable (Permanent) Mold, and Other. In these procedures mainly water & clay mold, Investment casting and die casting are famous sub process.

Investment casting is also known as lost wax casting, it’s one of the oldest metals forming technique. This process is ensure and guaranteed to produce superior and high quality components. In the investment casting foundry excellent and precise casting components are building, sometimes complex or critical design products also manufactured.

In the non-expandable casting mainly non-ferrous metals are used to produce casting parts, set up process of mold is time consuming but after that it produce around 10-50 pieces/hr-mold. These products are high in tensile strength compare to other casting. Generally iron, magnesium, aluminum alloys and nickel alloy casting are used to produce durable components.

Sand casting is one of the easiest and popular types of casting, it allows small groups to produce numerous number of casting such as 5-25 pieces/hr-mold. In this type of process most of the metals are applicable as per sand is used.

In the continuous casting production remain continuous with the help of reused and refinement mold. The product which are manufactures are premium in quality and strength, metals like steel, aluminum and copper are generally used to produce huge range of casting parts. This type of huge casting production is offered by Energy Technocast Pvt. Ltd. with an international standard and quality at the lowest price.

Last words, Different casting manufacturer uses various casting technique to produce high quality and durable casting components. Some of the other detailed casting types are available, hope present casting types are useful.

Waiting for your words and ideas in below comments.

Tuesday, 11 April 2017

Why is Lost Wax Casting so Famous?

Investment casting is a process in which pattern of parts are molded, the wax pattern of part design and coated with refractory ceramic substance. After the material becomes tough internal geometry takes the form of casting. This complete process is also known as Lost Wax Casting. The product should be manufactured using superior quality raw materials as per international standards and specification, to produce high quality casting equipment. If the primary material is lower in quality then final casting product may be unwanted and faulty for longer period.

The casting design and specification may differ as per industrial requirements and usage of the customers. With the help of accurate and precise investment casting various parts like aerospace parts, power plant boiler parts, non-ferrous and ferrous parts, marine parts, industrial valves & pumps, firefighting equipment, jewelry, turbine blades etc. are manufactured. 

In the investment casting generally two procedure are followed, Silica Sol Process and Water Glass Process. Silica sol process mainly used for manufacture smaller design parts while Water glass process used for larger design parts like grey iron, alloy steel, carbon steel, and ductile iron. Apart from this lost wax casting is highly popular process to manufacture investment casting parts.

Advantages of Lost Wax Casting 
  1. This process provides higher design flexibility, means complex shapes casting parts can be possible.
  2. It provides greater details, close tolerances and excellent outward finishing.
  3. It’ll reduce material cost and produce near net cast products.
  4. It eliminates expensive and costly fabrications.
  5. With the help of lost wax any metal can be cast.

Disadvantages of Lost Wax Casting
  1. Labor cost is expensive
  2. The process of manufacturing is lengthy that’s why it’s time consuming process
  3. At one point casting size can’t exceed
  4. Rarely or occasionally found faults

  • Medical field
  • Automobile industry
  • Military
  • Marine
  • Defense
  • Industrial Gas Turbine
  • Industrial Pumps & Valves
  • Industrial boiler parts
  • Ferrous & Non-Ferrous parts
  • Firefighting parts

Last Words, Lost wax casting is highly popular and affordable manufacturing process, for better quality and finishing always follow this process. Looking forward to your views and ideas in comments.