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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.

Aerospace & Defense Market Experience

Posted by Dave Olsen on 7/14/20 11:36 AM

The Aerospace and Defense industry stretches the limits of performance and as a result, these markets demand perfection. Engineering collaboration with MetalTek helps meet those challenges with innovative products and processes. There are numerous examples of where MetalTek's alloy development or process capability has enhanced the performance of components used in the Aerospace and Defense markets.

Below are just a few examples of MetalTek's experience in these demanding markets.

Hub Body For Naval Destroyers

Exhaust Manifold For Army Tanks

Landing Gear Components For Aircraft

Firing Check Valve For Naval Applications

Tow Bellmouth For Littoral Combat Ship

Winch Drums For Navy Ships

Combustor Cover For Army Tanks

Benches For Pentagon Memorial

Airflow Body For Aircraft

Rocket Engine Nozzle

Injector Dome For Rocket Engines

Fuel Manifold For Aircraft

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Topics: Investment Casting, Sand Casting, Centrifugal Casting, Casting Process, Lost Wax Casting, Defense, Conversion, Aerospace

Aerospace & Defense Market - General Overview

Posted by Dave Olsen on 7/10/20 1:53 PM

Blue Chip companies in the aerospace and defense markets rely on MetalTek International for their metal casting needs. Your market demands perfection and MetalTek not only has the required certifications, but our Sales Engineers are industry specialists that understand your market. But even beyond our capabilities of what we can produce, MetalTek partners with you to make your products and businesses better. We only succeed when you are successful.

AEROSPACE MARKET:

An integrated manufacturing process that includes centrifugal, investment, sand, and continuous casting, along with machining lets customers in the aerospace market know they are working with metals experts. 

This approach allows the engineering and supply of net shaped product, providing the intricacy of investment casting with the integrity of centrifugal casting. Near net shaped components can be produced to provide large O.D. features that minimize post processing in nearly any quantity.

Bearium Metals' products are on the NASA launch pad and on Mars! Our Sales and Engineering teams dedicated to the Aerospace market ensure that you get the attention, expertise, and performance that you deserve. Bearium is often the basis design where regular lubrication is difficult or impossible. It has shown the same long life and superior performance in cryogenic environments as well.

From mandrels and forming dies to critical components for rocket engines, allow MetalTek to serve you and your metal needs. 

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Topics: Investment Casting, Sand Casting, Centrifugal Casting, Casting Process, Lost Wax Casting, Defense, Conversion, Aerospace

Metal Casting vs. Metal Forging: 5 Things to Consider

Posted by Dave Olsen on 4/7/20 2:13 PM

While metal casting might be the best process to manufacture a wide range of components, depending on your needs, a forging could be the best option. Or vice-versa. Here are 5 things to consider when deciding if a casting or forging is right for your component, application, and overall needs. 

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Topics: Investment Casting, Sand Casting, Centrifugal Casting, Process Selection, Casting Process, Lost Wax Casting, Conversion

4 Real Life Examples Of Solving A Heat, Wear, Or Corrosion Problem

Posted by Dave Olsen on 12/16/19 2:32 PM

The days when manufacturers had a host of technical experts on staff are past in many industries.  And this at a time when material choices are broader and product performance demands are higher than they have ever been.  So the situation will not get any easier. Here are just four real life examples where MetalTek International helped a customer's heat, wear, or corrosion problem.

If you have a question about alloy selection, if you manufacture products that operate in harsh corrosive, high wear, or extreme temperature environments, or if you are simply looking to improve product performance, contact MetalTek.

  1. Bearium Solves Load and Friction Problems in Mobile Crawler
    From the days of Apollo program through the Space Shuttle a heavy duty crawler has carried the enormous weight of space vehicles down the one-mile path to the launch pad. Early designs used to carry this load were subject to sudden catastrophic failures of the roller bearings, jeopardizing timing of the launches. The crawler went through an emergency redesign to replace the roller bearings with sleeve bearings manufactured using Bearium B-10, a high-lead bronze that is only available from MetalTek International. Designs using Bearium delivered acceptable performance in an application that would then feature much higher friction. Bearium is used in the space craft crawler application to this day.
  2. Creating a “Memorial to Last a Lifetime” 
    Working with architects to create a “Memorial to Last a Lifetime” is no small task. Every step of program management is critical—from materials and engineering, to budget compliance, to execution. Initially, the Pentagon Memorial team approached MetalTek International about choosing the “right” alloy to last 150 years; as various materials were trialed and budgeted, the ultimate selection came down to a restricted-range 316LN (CF3MN-Mod) alloy that would meet the design requirements and still be producible to tolerances such that 184 Memorial Units, each weighing over half a ton and measuring over 12’ (4m) in length, would seem to be “identical.” Specialized tooling, processing and fixtures were developed, trialed, and modified against an aggressive timeline. In the end, MetalTek met the Vision, the Budget, and the Schedule.
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Topics: Alloy Selection, Corrosion Resistance, Wear, Casting Process, Conversion, High Heat

5 Examples When Castings Were Better Option vs. Fabrication or Forging

Posted by Dave Olsen on 12/10/19 4:36 PM

Partnering with a supplier that brings a full range of metalworking processes lets you be confident that you are getting the best metalworking advice – and not just being sold on an idea because it is the only answer a supplier has. The replacement of multi-piece weldments or highly-machined hogouts by single piece castings has been proven time and again to be one of the most effective ways to reduce real product cost. Here are just five real-life examples of when the casting process was a better choice for the customer than a fabrication or forging. 

#1.) Centrifugal Casting Replaced Complex Fabrication
Controllable pitch propulsion (CPP) systems provide the ability to alter the angle of the ship’s propeller while in use, allowing for different performance during cruising and maneuvering. A centrifugal hub provides the strength and size needed to transfer up to 50,000 shaft horsepower to five attached propeller blades. The hub and 15 other accessories that MetalTek produces for the CPP must perform in corrosive environments for the life of the vessel. Fabrications previously used were very intricate, with multiple pieces and welds, and much machining. The single piece nickel aluminum bronze hub that MetalTek has supplied for 35 years is the largest, most complex centrifugal casting ever produced. The use of a single piece part in this application eliminates welded joints and defects in those fabrications that are only discovered after finished machining.

#2.) Fabrication Could Not Achieve Dimensional Stability
International research, including that done in conjunction with the DOE, strives to create conditions in the lab necessary to support nuclear fusion.  Huge machinery, such as the “Z-Machine”, can create temperatures of 2.9 million °F (1.6 million °C) for fractions of a second.  Integral components must have the ability to conduct electricity and perform in the machine’s water cooling system.  Attempts to use fabrications in those applications were abandoned because dimensional stability could not be achieved.  The customer came to MetalTek for a casting solution, a particularly challenging one because of the product’s large size.  MetalTek specializes in large investment castings, and now supplies products with better dimensional consistency than was available with a fabrication.

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Topics: Investment Casting, Sand Casting, Centrifugal Casting, Continuous Casting, Process Selection, Casting Process, Lost Wax Casting, Conversion

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