When done right, weld repaired castings are just as structurally and functionally sound as their non-welded counterparts. However, weld repair in steel castings is often misunderstood by casting customers. Some companies simply do not allow weld repair, and others place strict requirements on where weld repair can take place on a part. By better understanding the effects of weld repair on part appearance and functionality, casting customers can benefit from weld repair strategies that optimize cost, production time and part quality.
Design for Manufacturability, or DFM, is an engineering practice that takes into account not just the way a product will look or function, but also how it will be produced. By applying DFM principles to new or existing products, manufacturers can improve product quality while optimizing cost and delivery time.
According to Eagle Alloy CTO, Nic Tarzwell, "DFM is the measure of all the steps involved to produce the component cost effectively while ensuring it meets (or exceeds) expectations of form, fit and function." In order to optimize Design for Manufacturability, the customer and the supplier must work together to determine the best design and process for producing quality-finished products at the least cost.
Tooling in metalcasting and CNC machining refers to reusable items that are specific to each job. In investment casting, tooling is considered to be wax-injection dies used to create wax patterns. If you're familiar with how investment casting works, you already know that these wax patterns form the basis of the investment casting process. Each part begins as a wax pattern, and the properties of wax – smooth surface, low melting temperature and excellent flow properties – that make highly complex investment castings possible.
This introduction to metalcasting provides a brief overview and history of the casting process, as well as an outline of common casting techniques in use today. The goal of this article is to give new manufacturers a better understanding of how metalcasting works and what steps are involved in producing cast products. By the end of the article, the reader should have a clear picture of the opportunities presented by metalcasting, and a sound appreciation for its potential as a modern manufacturing method.
Metalcasting is a modern manufacturing industry, and cast products are utilized in 90% of durable goods, from lamp posts to space shuttles. Still, no casting is perfect. Even with recent innovations in simulation and process technology, nearly every cast product will contain some level of defect. A clear understanding of casting defects is vital for any casting customer, as it helps guide realistic expectations when working with a casting facility.
While experienced casting facilities are skilled in finding a balance between cost and quality, purchasers should be closely involved in determining admissible levels of defects in deliverable products.
Grinding is a machining process using abrasive surfaces to remove material from metal workpieces. On the surface (pun intended) grinding may seem different than other machining processes, but it still works through chip formation and removal–just like sawing, milling, broaching and most other techniques. Grinding can produce surfaces conforming to rough or extremely close tolerances. Because of its versatility, grinding is used for simple gate removal in castings as well as advanced finishing processes like polishing and sharpening.
ESOPs are growing in popularity among businesses around the United States. They allow company owners to transfer ownership to employees by distributing stock, creating excellent retirement benefits and promoting stability and longevity for the company. Both Eagle Alloy and Eagle Precision have ESOPs in place.
Eagle Alloy celebrated 40 years of business last weekend with a large 40th anniversary party. Founded in 1979 to meet the needs of customers looking for a short-run steel foundry and stainless steel foundry, Eagle Alloy has grown into a successful casting facility that aggressively competes globally. After four decades, we have a lot to celebrate.
Broaching is a machining process using a cutting tool with teeth that increase in size from front to back. In many cases, an entire surface (or multiple surfaces) can be finished in a single pass with broaching. The technique is most often applied to finish holes, splines and flat surfaces.
Broaching is a relatively new machining process, developed in the 1850s with metal-specific applications. Originally, broaching was used to perform work on internal characteristics, like keyholes in pulleys and gears. During the 20th century, broaching was further developed for use in firearms, and subsequent developments have dramatically improved tolerances and made broaching more versatile for modern machine shops.