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FROM THE DESK OF THE METALS EXPERTS

Welcome to the MetalTek Blog.

As your Metals Partner, it is our goal to educate you on various casting processes. Feel free to browse around to learn more but if you have questions or need to submit an RFQ, please contact us. MetalTek International. Because You Demand More Than Metal.

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Sand Casting Process: Featured Solution Examples

Posted by Dave Olsen on 8/3/17 2:45 PM

Think of a test that you face in metal component design or application. Here are some examples of where leveraging the advantages of sand casting have helped solve an application challenge.  Maybe you will see a problem you are working to resolve.

High performance needs combined with light weight

Military hardware transported by air to the place it is needed must be ready to perform, but also must be light enough to be portable. “Box Beam” sand casting sets in radiographic quality 17-4PH stainless steel ranging up to 1,000 lbs. and 14’ in length provided the needed strength and weight.  The solution was a result of work to select the alloy grade that delivered the needed performance with the right strength to weight ratio, and then producing to the standard.

Design and Tooling Capability Saves Development Time

Quick performance, perhaps caused by the need to rapidly develop alternative sources, relies in part on robust design and tooling capabilities.   ProE and AutoCAD for in-house design, Magma Soft for solidification simulation takes time and guesswork out of the design process.  When combined with the ability to supply patterns in wood, synthetics, metals, and other materials the upfront time to get into production quickly.

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Topics: Sand Casting, Casting Process

Sand Casting Process: Advantages and Limitations

Posted by Dave Olsen on 8/3/17 2:09 PM

Advantages of Using Sand Casting

Nearly any alloy:  Sand castings can be readily produced in nearly any ferrous or non-ferrous alloy.  Some other casting processes will melt and pour super-alloys in vacuum, but that is not typically done as a sand casting. Some materials cannot be “worked”, and must be produced as a casting.

Low tooling cost:  The relatively low cost of tooling makes sand casting a process of choice for lower volume needs.  Patterns do wear, though, so the material selected for the pattern (typically wood, plastic, or metal) will depend on the expected usage quantity of the part being produced. Though not necessarily cheaper in the short run, the use of machined (or “patternless”) molds may be a cost effective option for components with expected lower usage over longer periods.

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Topics: Sand Casting, Casting Process

What is Sand Casting and How Does It Work?

Posted by Dave Olsen on 8/3/17 1:57 PM

Sand Casting

The oldest known casting process, sand casting can be traced back to earlier than 1000 B.C. Process controls, material options, tolerance capabilities, the ability to produce elaborate parts, broad size ranges – those have all come a very long way, of course.  But the metals fundamentals are relatively unchanged.  Create a cavity in the shape of the part you want, and pour molten metal into it. 

The result of centuries of development is that sand casting is the most versatile, and probably the most widely used, metal casting method.

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Topics: Sand Casting, Casting Process

MetalTek's Wisconsin Centrifugal Division Reaches Two Million Hours Without A Lost Time Incident

Posted by Dave Olsen on 5/31/17 1:22 PM

Press Release

May 31, 2017

METALTEK WISCONSIN CENTRIFUGAL REACHES TWO MILLION HOUR SAFETY MILESTONE

WAUKESHA, WISCONSIN – MetalTek International announced today that its Wisconsin Centrifugal Division has surpassed two million man hours worked without a lost time incident at their operations located in Waukesha, Wisconsin. This safety record at MetalTek's Waukesha site has extended well over two years.

This safety milestone is a direct result of each MetalTek employee’s personal dedication to safety awareness and practices. This achievement reflects the solid safety program at Wisconsin Centrifugal supported by a behavior-based safety culture, management commitment to continuous safety training, inspection and monitoring activities, and an enhanced incident review process. Wisconsin Centrifugal General Manager Eric Skibo noted, “Safety is front of mind every day.

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Topics: Press Release

Investment Casting Process: Featured Solution Examples

Posted by Dave Olsen on 4/21/17 4:37 PM

Think of a test that you face in metal component design or application. Here are some examples of where leveraging the advantages of investment casting have helped solve an application challenge.  Maybe you will see a problem you are working to resolve.

Minimizing Casting Upgrades Or Additional Processing

While all applications are expected to perform, some industries like defense and aerospace are even less tolerant of products that need upgrade prior to use. Investment castings that require minimum machining or other processing, including those produced using processes compliant with demanding standards like Nadcap, offer the best opportunity to save time, cost, and ensure that essential equipment continues to perform.  

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Topics: Investment Casting, Casting Process, Lost Wax Casting

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