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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.

Shaped Centrigual Castings

Posted by Dave Olsen on 10/10/18 3:41 PM

Centrifugally cast components are typically thought of as straight walled cylindrical geometries such as tubes, pipe, or rings. They are often cast horizontally in permanent steel dies that have a removable end cap.  Because the part must be extracted from the uncollapsible die, shaping is limited to geometries that have a straight or slightly drafted O.D. 

While the majority of centrifugals are straight walled pipe or tubing cast horizontally, it is common for centrifugals to have more complex shape.

MetalTek utilizes a vertical axis of rotation and more complex dies using tapers, counterturns and removable sections to  produce centrifugals with cast flanges, tapered walls, and asymmetric geometries. Near-net and net-shaped centrifugals are typically poured into a   vertically spinning, formed, consumable mold.  The mold is typically sand, ceramic, graphite, metal, or a combination, depending on geometric complexity, size, production process, etc. The result is a part that may require virtually no O.D. machining.

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Topics: Centrifugal Casting, Vertical Casting, Near-net Shaping, Shaped Parts

Centrifugal Casting Process: Advantages and Limitations

Posted by Dave Olsen on 7/17/18 10:25 AM

Advantages

Centrifugal Casting Eliminates Mid-wall Defects

  • The centrifugal process does not rely on discrete risers or feed points to ensure the absence of trapped porosity. Rather, the inner diameter remains fully liquid during the solidification process, resulting in a continuous supply of metal to feed areas of contraction.
  • Unlike conventional gravity or static castings that chill from both the inside and outside surfaces and risk trapping mid-wall shrinkage, centrifugal castings solidify from the outside surface inward. The result is a part consistently free of shrinkage cavities, gas pockets, and blowholes.

Centrifugal Casting Controls Impurities

  • Unique to the centrifugal process is the high force that effectively isolates less dense substances in the casting’s bore area. These impurities are later machined away, leaving a defect free part. Molten metal is fed into a rotating mold where a centrifugal force of up to 100Gs is applied to the metal. Centrifugal force is critical for this process. The Gs produced are dependent on the RPM and diameter of the die.
  • The centrifugal force pushes high density metal against the mold sidewall while lower density components migrate or "float" toward the I.D. These lower density items include metal oxides, sulfides, gas, and other impurities that would otherwise have been inclusions in the casting. This phenomenon is termed “secondary refining”.
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Topics: Centrifugal Casting, Horizontal Casting, Vertical Casting, Casting Process

What is Centrifugal Casting and How Does It Work?

Posted by Dave Olsen on 7/17/18 9:46 AM

Overview

Centrifugal casting is a process that delivers components of high material soundness. As a result, it is the technology of choice for applications like jet engine compressor cases, hydro wear rings, many military products, and other high-reliability applications. It has also proven to be a cost-effective means of providing complex shapes with reduced machining requirements and lower manufacturing costs as compared to forgings and fabrications.

In the centrifugal casting process, molten metal is poured into a preheated, spinning die. The die may be oriented either on a vertical or horizontal axis depending on the configuration of the desired part.

By spinning a mold while molten metal is poured into it, centrifugal force acts to distribute the molten metal in the mold at pressures approaching 100 times the force of gravity. The combination of this applied pressure and the engineering mechanics of controlled solidification and secondary refining produces components of superior quality.

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Topics: Centrifugal Casting, Horizontal Casting, Vertical Casting, Vacuum Casting, Solidification, Casting Process

Near-net Shaping Process: Featured Solution Examples

Posted by Dave Olsen on 4/18/17 2:29 PM

Think of a problem that you face in metal component design or application. Here are some examples of where leveraging the advantages of near-net shaping have helped MetalTek and a customer work together to solve an application challenge.  Maybe you will see a problem you are working to resolve. For more information regarding to any of your metal applications, please Contact Us.

Near-net Shaped Centrifugals Reduce Scrap Costs

When supplied as a static casting, defects in certain valve components are often not discovered until much machining had been completed. The results are very high scrap rates and cost.  Working with a specific customer facing this, MetalTek engineers converted the static casting to a centrifugal, incorporating sand core technology into the design of the existing part.  The homogeneous quality of a centrifugal casting reduced hidden defects.  The rough casting was designed so that the last machining pass on the I.D. of the part opened the windows, minimizing the number of interrupted machining cuts.  This further drove down scrap, which has been reduced by 98%.

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Topics: Vertical Casting, Casting Process, Near-net Shaping

Near-Net Shaping: Combining Shaping Technology with the Centrifugal Process

Posted by Dave Olsen on 4/18/17 2:10 PM

Overview

Near-net shaping combines various shaping technologies, such as sand casting and investment casting, with the high-integrity centrifugal process to maximize the benefits of each. Net-shaping can be readily added to add O.D. profiles to centrifugally cast components through the use of sand, ceramic, or split graphite dies. True net-shaping at investment casting levels of O.D. detail can be added by employing MetalTek’s proprietary net shaping technology and special tooling.

In addition to reduced cost due to savings because of reduced metal used, near-net shaping and net shaping centrifugal casting enables tighter quality control, especially in applications where alloy solidification behavior is a problem. Finally, since shaping is casted in versus machined in, customers realize a savings in machining costs.

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Topics: Centrifugal Casting, Vertical Casting, Casting Process, Net Shaping

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