admin – Investment Casting, Lost Wax Casting China

Carbide pad applied on the centrifugal separator

05/07/2025 admin

Why Choose Small hard alloy pad Welding Technology in Decanter Centrifuges?

Comparison of Wear-Resistant Technologies Among Major Brands

Brand	Gasket Welding	Alternative Technology	Application Areas
ANDRITZ	✅ Yes	Small tungsten carbide gaskets	Municipal, Biomass, Chemical
Flottweg	✅ Yes (some models)	Replaceable liner + welded gasket modules	Hazardous waste, Mineral processing
Alfa Laval	❌ No	Zirconia ceramic covering	Food, Marine, Mining
Westfalia	❌ No	Ceramic coating, Alloy inlay	Pharmaceuticals, Fine chemicals
Pierre Reis	❌ No	Carbide spraying + Alloy spiral	Mining, Oil drilling

Key Benefits of Small Wear-Resistant Pads

The spiral blades in decanter centrifuges are exposed to intensive abrasive wear due to continuous contact with solid particles such as:

Mineral fines
Crystalline salts
Biomass residues
Metal fragments

Welding small carbide pads to the screw conveyor blades addresses these issues effectively.

Advantages Include:

✅ Superior Abrasion Resistance: Protects against high-hardness materials in contact zones.
✅ Reduced Maintenance: Sacrificial pads absorb wear, protecting the main spiral blade.
✅ Extended Equipment Life: Delays the need for expensive part replacements.
✅ Lower Downtime: Minimizes operational interruptions due to wear-related failures.

Why Weld Multiple Small Gaskets Instead of One Large Plate?

Adapts to Complex Curved Surfaces: Easier installation on helical blade geometries.
Distributes Stress & Impact: Reduces crack risk due to thermal/mechanical stress.
Simplified Maintenance: Damaged gaskets can be selectively replaced.
Enhanced Welding Quality: Smaller weld zones improve structural integrity.
Cost-Effective Over Time: More targeted protection with reduced material waste.

Case Studies: Brands Utilizing Gasket Welding

ANDRITZ

Technology: Dense welding of small tungsten carbide gaskets (10–20 mm) on blade surfaces.
Advantages: Excellent coverage of high-wear areas, replaceable modules, strong substrate bonding.
Use Cases: Municipal sludge, biomass waste, chemical sludge.

Flottweg

Technology: Modular wear liners with welded carbide blocks or strips.
Advantages: Dual protection (liner + gasket), high replacement efficiency.
Use Cases: Hazardous industrial waste, mineral tailings.

TCC’s Contribution: Custom Casting & Welding of Carbide Gaskets

TCC Co., Ltd specializes in producing high-quality cast carbide gaskets, supporting welding services with strong material compatibility.

Materials Commonly Used:

Material	Key Feature	Typical Application
Tungsten Carbide (WC-Co)	Ultra-hard, durable	Mineral wear, solids processing
Chromium Carbide (Cr₃C₂)	Corrosion-resistant	Chemical and biomass slurry
NiCr-Si-B Alloys	Weldability, thermal match	Stainless steel blades, uniform stress
Cermet	Thermal shock resistance	High-temp drying, crystallization

Advantages of Cast VS Machined Gaskets

Complex Shapes in One Step: Cast gaskets fit curved surfaces more naturally.
Material Gradient Design: Can embed cores with different thermal/mechanical properties.
Scalable Cost: Casting becomes economical for high-volume, high-alloy content parts.

Welding Methods and Process Control

Common Welding Techniques:

Brazing: For low-stress or smaller parts; uses Ni or Ag-based filler.
Plasma Arc / Laser Welding: Precision, low distortion, ideal for thin blades.
Surfacing + Composite Welding: For enhanced impact and wear performance.

Process Control Tips:

Preheat and slow cooling to reduce cracking risk.
Maintain strong fusion and proper weld penetration.
Use staggered multi-point welding to minimize distortion.

Industry Trends

📌 Standardized modular gasket systems are gaining popularity.
🤖 Asian manufacturers have adopted automated gasket welding machines.
🔍 Smart monitoring systems now provide wear tracking and replacement recommendations.

Conclusion

The welding of small wear-resistant carbide pads onto decanter centrifuge spiral blades is a technically efficient, cost-effective, and scalable solution for industries facing harsh abrasive environments. TCC offers robust capabilities in casting, material matching, and welding—making it a reliable partner in extending the life and performance of high-value rotating equipment.

The method of welding for the defects of Aluminum alloy parts

01/07/2025 admin

Which welding is the better option for the defects of Aluminum alloy parts , argon arc welding (TIG/MIG), laser welding or cold welding ?

Think about the logic for selection ,

Deformation-sensitive parts (such as machined products): cold welding → laser welding → argon arc welding
High-strength parts : laser welding → argon arc welding → cold welding
Thick and large parts/low-cost repair : TIG welding → Laser welding (high power)

These are based on a detailed comparison of the core differences, characteristics and welding deformation of argon arc welding (TIG/MIG), laser welding and cold welding . The further specific analysis is as below :

1. Basic principles and core differences,

Method	Principle	Heat input characteristics
TIG welding	The base metal and welding wire are melted by electric arc (non-melting electrode TIG/melting electrode MIG), and argon gas is used to protect the molten pool from oxidation.	High heat input and wide heat affected zone.
Laser welding	The high-energy laser beam melts the metal instantly, and the argon/helium gas is used for protection, which is a high-energy density fusion welding.	Concentrated heat input and narrow heat affected zone.
Cold welding	High-pressure plastic deformation (solid-state welding) or micro-arc discharge (micro-melting) achieves atomic-level bonding with virtually no heat generation.	Very low/no heat input , no heat affected zone.

2.The Comparison of heat affected zone width,

3. The Comparison of core features,

Characteristic	TIG/MIG welding	Laser welding	Cold welding
Heat input	High, wide heat affected zone (prone to grain coarsening)	Concentrated, narrow heat-affected zone (about 1/3 of argon arc welding)	Virtually no heat input , no heat affected zone
Welding speed	Slow (TIG) to medium (MIG)	Very fast (up to 10m/min)	Slow (spot welding/repair)
Melt Depth	Medium-deep (current dependent)	Deep and precisely controllable (high aspect ratio)	Very shallow (surface binding only)
Oxidation Control	Depends on the purity of argon gas. Aluminum alloy needs AC TIG to break the oxide film	Requires high-purity protective gas, sensitive to oxide film	No oxidation problems (normal temperature operation)
Joint strength	Close to the parent material (need high-quality welding wire and process)	≥ Parent material (deep melting welding with high density)	≤ Parent material (joining surface is the pressing area)
Applicable thickness	Thin-Thick (0.5mm~25mm+)	Thin-medium thick (0.2mm~12mm, high power up to 20mm)	Ultra-thin (≤2mm, repairing micro defects)
Equipment cost	Low (TIG) / Medium (MIG)	Very high (laser + precision motion system)	Low-Medium (Press/Micro-arc Equipment)
Technical Difficulty	Medium (TIG requires skilled workers, MIG is easy to automate)	High (needs precise parameter adjustment, centering, and protection)	Low (simple operation, mainly pressure control)
Typical Applications	Structural parts, containers, special-shaped welds	Precision parts, battery housings, aerospace parts	Precision repair (pores, scratches), electronic components, heat-sensitive parts

4. The Comparison of deformation after welding,

Method	Deformation Source	Deformation degree	Control Difficulty
TIG welding	High heat input → severe thermal expansion and contraction , large residual stress, thin parts are prone to warping and corner deformation	★★★★★ (maximum)	Thin plate deformation is difficult to control, requiring strong fixture + anti-deformation design
Laser welding	Heat input is concentrated, but aluminum alloy conducts heat quickly → local shrinkage stress is still significant (especially in long welds)	★★★☆☆ (Medium)	Parameter optimization can reduce deformation, but it is difficult to completely eliminate it
Cold welding	No thermal stress , only micro plastic deformation caused by pressure	★☆☆☆☆ (very small)	Almost no macro deformation, suitable for high-precision parts repair

5.The key points of Deformation control,

Argon arc welding : requires pre-setting of anti-deformation, segmented skip welding, and water-cooling tooling, and correction is often required after welding.
Laser welding : Pulse welding, high scanning speed, and optimized path can reduce deformation, but fixtures are still required.
Cold welding : uniform pressure is sufficient, close to “zero deformation” , and no secondary processing is required after repair.

6. Suggestions,

Pursuing zero deformation → cold welding
▶ Applicable scenarios: repair of precision instrument parts, thin-walled parts (≤2mm), heat-treated parts, electronic housings.
▶ Limitations: low strength requirements (≤80% of parent material), limited to small area repairs.
Balance strength and deformation → Laser welding
▶ Applicable scenarios: aerospace parts, sealed housings, battery welding (deep melting requirements), automated production lines.
▶ Key: High equipment investment, suitable for mass production.
Cost priority, accept controllable deformation → TIG welding
▶ Applicable scenarios: large structural parts, thick plates (>5mm), non-standard single-piece production.
▶ Skills: TIG is used for high-quality welds, MIG improves efficiency; the surface of the welding material needs to be strictly cleaned.

Conclusion,

Dimensions	TIG welding	Laser welding	Cold welding
Heat input	high	Medium-High (Concentrated)	none
Deformation	great	medium	Very small
strength	High (close to base material)	Very high (deep melting and dense)	Medium-Low
cost	Low	Very high	middle
Best Scenes	Thick plates, structural parts	Precision parts, deep melting requirements	Ultra-thin parts, zero deformation repair

The influence of material properties on welding repair selection

The different materials of aluminum alloy have significant differences in adaptability to welding repair methods due to differences in alloying elements, heat treatment characteristics, etc.,

Material Category	Feature	Optimal welding method
6xxx series ( Al-Mg-Si )	Heat treatment strengthened type, difficult to restore mechanical properties after welding	Laser welding / cold welding (low heat input)
5xxx series (Al-Mg )	Non-heat treatment strengthening, stable performance after welding	High suitability for MIG/ cold welding
2xxx series (Al-Cu )	High crack sensitivity, difficult welding	Laser welding requires preheating + post-heating
7xxx series (Al-Zn-Mg )	High strength, easy to soften	Cold welding is suitable for small area repairs, laser welding should be used with caution

Post-weld heat treatment/correction needs assessment

The impact of different welding methods on subsequent processes is as follows,

Welding method	Need heat treatment after welding?	Need Shaping calibration?	Precautions
TIG welding	T6 state is required , reheat treatment is recommended	Need (especially thin parts )	Easy to warp
Laser welding	Small thermal impact, generally no need	May need	High automation precision but high equipment cost
Cold welding	No	No	Fine repair is suitable, and structural parts are used with caution

The application of texturing on casting

24/06/2025 admin

Texture or Texturing is a technology that forms specific textures by chemically etching or laser processing the surface of metal molds. These textures will eventually be transferred to the surface of plastic or metal products, achieving both decorative and functional effects. The texture process has clear feasibility in the casting field (especially die casting) . By improving the heat resistance of the mold, deepening the texture depth, and optimizing the draft angle , it can stably produce high-value-added metal parts. The future trend is to combine 3D laser engraving with mold temperature control technology to solve the problem of texture deformation caused by high temperature.

The following are its wide application areas and technical features:

🔧1 . Main application areas

🚗Automotive industry

Interior parts : steering wheel (leather pattern), instrument panel, door panel (pear pattern or geometric pattern), etc., to enhance the touch and cover the mold line and shrinkage mark.
Functional parts : non-slip footrest, crash bar surface (increases friction).

📱Consumer Electronics

Mobile phone/computer cases (such as Galaxy S series, iPad protective cases) use laser biting to form delicate patterns (such as leather patterns and hair patterns), which are both beautiful and anti-fingerprint.
The surfaces of household appliances (audio, camera) use fine grain or matte finish to reduce reflections and hide processing defects.

🏠Building materials and bathroom

Bathroom tiles (imitation marble pattern, depth up to 3mm), door and window hardware (sandblasted pattern to resist scratching).
The surface of flower pots and tableware (stone or wood grain) enhances texture and personalization.

🖥️Industrial equipment and daily necessities

Office equipment (printers, keyboards) use satin texture, which is wear-resistant and comfortable to the touch.
Medical device handles (anti-slip texture), toy surfaces (cartoon geometric patterns).

⚙️2 . Technical characteristics and trends

🔬Traditional crafts
- Chemical etching : Use sulfuric acid, nitric acid and other solutions to corrode the mold to form leather grain, pear grain, etc. The disadvantage is that it relies on manual labor and has low environmental protection.
- Sand blasting : quickly produces uniform sand patterns, low cost but poor durability.
💡Modern technology: Laser Texturing
- Advantages :
  - No chemical pollution, precision up to 0.01mm (such as DMG five-axis laser equipment).
  - Supports complex 3D surfaces (such as automotive interior molds), and reduces working hours by 50% (a task that traditionally takes several days can be completed in 12 hours).
- Application : high-end automotive leather texture, 3C product precision texture.

The molds of the biting process can be fully applied to the casting process, especially in the field of metal die casting and gravity casting , but the process parameters need to be adjusted according to the casting characteristics. The following is a specific analysis:

✅1 . The core application of biting in casting process

1. Die casting mold (aluminum/zinc/magnesium alloy)

Surface treatment : Laser biting or chemical etching is performed on the surface of the mold cavity to form a texture (such as leather texture, fine sand texture), which is then transferred to the surface of the die-casting.
Examples :
- Automobile gearbox housing (anti-slip patterns improve operating feel).
- Laptop shell (aluminum alloy die-casting + hairline texture, replacing plastic injection molding).

2. Gravity/low pressure casting mold

Biting is used in engine block and wheel hub molds to cover metal flow marks or parting lines.

⚠️2 . Technical difficulties and solutions

Challenge	Casting process Characteristics	Countermeasures
High temperature corrosion	High molten metal temperature (aluminum: 700°C)	Use high heat-resistant mold steel (such as H13 surface nitriding treatment)
Texture wear	Strong scouring power of molten metal	Laser texturing depth ≥ 0.1mm (higher than 0.05mm for injection molding)
Demolding resistance	Large metal shrinkage rate (aluminum 6~8%)	Increase the draft angle by 50% (e.g. 5° or more for a texture depth of 0.1mm)
Surface Adhesion	Metals tend to react with molds	Chrome plating on mold surface (thickness 0.01~0.03mm)

🔧3 . Key process adjustments

Texture Design
- Avoid sharp edges and corners (to prevent turbulence of the molten metal and cause porosity).
- Anti-scour textures are preferred (such as cross grid texture > unidirectional straight texture).
Mould pretreatment
- The casting mold needs to be polished to Ra0.2μm or less before biting (to reduce the amplification of surface defects).
Laser parameter optimization
- The die-casting mold is suitable for high-energy-density fiber lasers (such as 1064nm wavelength, pulse frequency 20kHz) to ensure that the texture remains clear after thousands of castings.

🚀4 . Typical application scenarios

Automotive Parts
- Aluminum alloy door handles (anti-slip texture), center console bracket (matte fine sand texture).
Consumer Electronics
- Magnesium alloy camera body (leather texture), drone housing (geometric etching texture).
Industrial Equipment
- Hydraulic valve body (identification texture instead of marking), motor heat sink shell (pattern to increase heat dissipation area).

V. Comparison of economic benefits

Technology	Traditional casting smooth mold	Texturing mold (die casting application)
Secondary processing cost of products	Need sandblasting/electroplating	Direct molding, eliminating the need for post-processing
Mold life	300,000 times	150,000~200,000 times (recoverable after texture repair)
Added value	Basic functions	15%~30% premium (such as high-end tool handles)

In conclusion:

The texturing process has clear feasibility in the casting field (especially die casting). By improving the heat resistance of the mold, deepening the texture depth, and optimizing the draft angle , it can stably produce high-value-added metal parts. The future trend is to combine 3D laser engraving with mold temperature control technology to solve the problem of texture deformation caused by high temperature.

The application and casting process of AlMg5Si castings

13/06/202524/06/2025 admin

AlMg5Si (common grades such as EN AC-51400 or AlMg5Si1 ) It is a typical aluminum-magnesium-silicon casting alloy with excellent corrosion resistance, medium strength and good weldability , and is widely used in many industrial fields.

1. Main application areas and typical parts of AlMg5Si castings :

1. Shipbuilding and marine engineering

Hull structural parts (hatch covers, handrails, trusses, etc.)
Deck equipment (bases, housings, connections)
Offshore platform structures

Reason: Excellent seawater corrosion resistance, suitable for humid or salt spray environment.

2. Transportation (especially rail and commercial vehicles)

Railway vehicle body structure
Automobile chassis components (subframes, wheels, brackets)
Trailer structural parts

Reason: Higher strength-to-weight ratio and impact resistance.

3. Energy and power equipment

Wind turbine cabin structural parts
High voltage switch housing, electrical connectors

Reason: Certain strength, conductivity and corrosion resistance are required.

4. Building and structural parts

Curtain wall connection components
Aluminum formwork support system

5. Mechanical equipment

Pump body, housing
Industrial automation equipment parts

2. Characteristics and key points of AlMg5Si casting process

Compared with other cast aluminum alloys (such as AlSi7Mg , AlSi10Mg , AlCu4Ti , etc.), AlMg5Si has the following characteristics and points for attention during melting , pouring and solidification :

1. The oxide film is highly sensitive and requires a good protective atmosphere

The magnesium content is high and it is easily oxidized during the smelting process to form MgO .
Recommended use Inert gas protection (such as Ar ) or flux protection , especially during smelting and sub-packaging.

2. Strong air absorption, easy to produce pinholes

Mg reacts with hydrogen to increase the tendency to getter, thus:
- Refining degassing (such as rotor degassing, Ar /Cl composite gas) must be sufficient ;
- Melt processing should be carried out at low temperatures ( 690–720°C is recommended ) to avoid excessive temperatures that promote aspiration.

3.High requirements for the mold (mold)

The tendency of thermal cracking is relatively large, and the mold design should consider:
- Reasonable cooling system distribution
- Avoid combining thick sections with fast shrinking areas

4. The cooling rate needs to be controlled during the crystallization process

AlMg5Si alloy has a wide solidification range (about 30–40°C ) and shrinkage should be avoided:
- Reasonable setting of gate system and riser
- Sequential solidification control or pressure consolidation techniques can be used when necessary

5. Post-processing heat treatment methods are limited

T6 heat treatment (such as quenching + aging) is usually not possible because its strengthening mechanism mainly relies on solid solution rather than precipitation hardening;
Generally adopted Use in T5 or natural aging ( F ) state .

Summary of key comparisons :

Process	AlMg5Si Features	Differences from other aluminum alloys (such as AlSi10Mg )
Melting protection	Easy to oxidize, absorb	High magnesium content → more inert gas protection is needed
Degassing treatment	Hydrogen removal refining is required	Stronger than normal air intake AlSi Tie
Casting system	Sequential solidification design required	Easy to shrink and uneven cooling has a great impact
Heat Treatment	T6 is usually not performed	Not suitable for precipitation hardening

The following are The recommended parameters of AlMg5Si casting process are suitable for process scenarios dominated by gravity casting (sand mold, metal mold). It is also suitable for low-pressure casting, such as when higher density is required for the production of structural parts.

1. Melting and insulation

Project	Recommended parameters	Illustrate
Melting temperature	700–740 °C	Avoid excessive temperatures to reduce oxidation and aspiration
Insulation temperature	690–710 °C	Long-term heat preservation requires protective atmosphere or flux
Protection method	Argon, nitrogen or flux ( NaCl+KCl )	Prevent magnesium oxidation
Degassing treatment	Ar+ Cl₂ Or degas the rotor for 10–20 minutes	Control hydrogen content ≤0.15 ml/100g Al
Flux Recommendation	Special magnesium aluminum alloy flux, such as Foseco MTS 158	Anti-oxidation, anti-inclusion

2. Pouring

Project	Recommended parameters	Illustrate
Pouring temperature	710–730 °C (sand mold) 690–710 °C (Metal Type)	Fine-tune according to mold material and wall thickness
Mold preheating temperature (metal mold)	250–300 °C	Prevent cold shut and poor filling
Gate design	Bottom injection, flow rate control, sequential solidification	Reduce oxidation slag and shrinkage
Riser / Feeding System	It is necessary to set up a heat preservation cap or pressurized shrinkage compensation	The alloy has a wide solidification range and large shrinkage
Cooling control	Local chilling iron assisted solidification control	Prevent thermal cracking and shrinkage

3. Heat treatment recommendations

Heat treatment status	Recommended parameters	Illustrate
T5 (artificial aging after casting)	160–180 °C × 5–8 hours	Improved stability, slightly increased strength
F (Not heat treated )	–	Supplied in normal condition, maintain ductility
T6 heat treatment is not recommended	Easy to deform, no obvious reinforcement	Because its strengthening mechanism does not rely on precipitation phase

4. Reference values of cast properties (for comparison only)

Performance Indicators	Numerical range	Condition
Tensile strength (Rm)	180–250 MPa	Cast or T5
Yield strength (Rp0.2)	90–160 MPa
Elongation (%)	5–12%
hardness	HB 50–80
density	2.64–2.66 g/cm³

5. Precautions & Process Optimization Suggestions

Do not use iron tools to stir for a long time : high-magnesium aluminum alloys are prone to inclusion reactions;
The pouring system must be designed with an anti-eddy current structure to avoid inclusion of oxide film;
The mold or cavity should be kept dry to prevent explosion or holes;
Local reinforcement areas can be assisted by chill iron / pressurization to improve density .

against AlMg5Si is used for fire protection system parts (such as joints, flanges, housings, connectors, etc.) The riser size design suggestions and filling simulation scheme can be divided into two parts:

1. Riser design suggestions (mainly for gravity casting)

Fire protection system parts usually require No leakage, no shrinkage, high density , so the riser design must consider the following points:

1. Riser design principles

Project	Recommendations
Riser position	Place in the last solidification area of the part (usually at the top of a thick section)
Riser shape	Cylindrical or oval (easy to process)
Insulation treatment	Insulation riser sleeve + insulation covering agent
Feeding efficiency requirements	≥30% and has a sequential solidification path
Is the riser open?	Generally use open risers unless the pressure difference is well controlled

2. Riser size estimation method (based on Chvorinov’s law)

use Modulus Method ) Design riser :

Modulus M ( Modulus ) = V / A
- V = volume ( cm³ )
- A = heat dissipation area in contact with air or die ( cm² )

Recommended size relationship:

Notice : The riser should use an insulating sleeve (such as an Exothermic sleeve ) to increase the effective shrinkage compensation volume by 30–50% .

3. Riser neck connection design

Parts module M ( cm )	Riser modulus (need to be ≥ 1.2×M )	Typical riser diameter × height ( mm )
M = 1.0	≥1.2	Ø30 × 35
M = 1.5	≥1.8	Ø45 × 50
M = 2.0	≥2.4	Ø55 × 60
M = 2.5	≥3.0	Ø65 × 70

The riser neck (the part connecting the riser to the casting) needs to be controlled to solidify slowly , with a modulus slightly lower than the riser but higher than the thickness of the casting.
Recommendation: Neck diameter = 1.2-1.5 times the wall thickness of the part , and the length should be controlled between 20-40mm to facilitate cutting.

2. Filling and solidification simulation scheme (simulation ideas)

It is recommended to use MAGMASOFT® or ProCAST ® For numerical simulation, the following are the simulation parameters for typical medium – sized flange joints (wall thickness 10-15mm ) in fire protection systems :

1. Simulation target

Confirm whether the solidification path is sequential
there porosity ?
Whether inclusions are generated ( Oxide Trap )
Is it cold shut or insufficient filling?

2. Simulation setup recommendations

Parameters	Setting suggestions
Alloy Model	AlMg5Si (user defined or input data via thermal analysis)
Wall Thickness Area Mesh	≤1.5 mm grid accuracy
Pouring temperature	710 °C (metal type) or 730 °C (Sand mold)
Mold temperature	250 °C starting
Gate speed	0.3–0.8 m/ s (to prevent air entrainment )
Cooling method	Local chilling (set temperature boundaries to 50–80°C )
Riser heat balance setting	Enable the insulation sleeve data parameters to simulate the delayed solidification effect of the riser

3. Output analysis key diagram:

Solidification Time distribution diagram → Determine the solidification order
Porosity Map → Check whether the shrinkage compensation is successful
Velocity Field diagram → Analyze the filling path
Oxide Formation → Determine whether to switch to the bottom injection channel system

Conclusion Recommendation

For fire protection flange parts, using Ø50×60mm insulation riser + symmetrical arrangement of chillers can effectively compensate for shrinkage;
For large size connectors or housings, it is recommended to use Top injection + double riser system , with internal riser if necessary;
2-3 times of scheme comparison and optimization in the early stage of development (different gate / riser combinations can be set);
If the casting is large and the thickness varies greatly, consider using Low pressure casting + local cooling channels optimize density.

Casted Open Wire Rope Socket of Carbon Steel with 1.7231 (42CrMo)

17/07/202104/08/2021 admin

The open wire rope spelter socket is the most important accessories for ropeways, structural applications and mining applications.The steel castings are used with ropes for safety critical applications such as load carrying structural members in structures frequented by people.

Being the manufacturer of a well-known structural rope company in Europe, TCC is experienced to manufacture from 1kg to 20kg different wire rope end connections . TCC ‘s steel castings is suitable for ropes to EN 12385 and applications to EN 1993.

The operating temperature for the steel castings and ropes is -50°C to +120°C.The Charpy Value is required K ≥ 27J at -20°C . The open socket is 100% has Type 3.1 of Certificates EN 10204.

For the material made by 1.7231 (42CrMo), as the unalloyed and low-alloyed steel castings are usually ordered with a zinc coating, typically applied by hot dip galvanization.These are two key processes for this rope end connection .With experienced treatment in this open sockets , TCC has these processes fully under control .

Tests and inspections shall be carried out in accordance to EN10204.

TCC provide a complete manufacturing service solution for each project and application.For more information on Wire Rope Socket, whether the carbon steel or stainless steel , please feel free to contact us.

When consider Aluminum Casting?

23/05/202129/07/2021 admin

If you are familar with aluminum parts, you may also be interested in the forming processes of them, mainly including casting, forging and machining. Casting is a process that allows foundries to create products with complex shapes while light weight. The process begins by creating molds. Then, workers pouring melton aluminum alloy into molds to achieve desired shape.

Benefits of Aluminum Casting Process

Only Aluminum Casting Can Produce Intricately Designed Parts

One of the best reasons why a wide variety of industries and consumers choose aluminum casting is the fact that it allows the manufacturer to produce aluminum parts that have intricate designs. In other words, it’s possible for them to order customized aluminum castings that perfectly suit their production needs.

The Production Process of Aluminum Casting is Faster than Machining

With aluminum casting, you’ll be able to produce parts faster than machining process? Since it allows you to create near-net shapes, you can easily eliminate the process of machining to get your desired results. This implies that with aluminum casting, you’ll be able to produce the finished parts much sooner than you initially expected.

Aluminum Casting is Very Affordable

If you want to obtain top-quality metal products at a much cheaper price, choose aluminum casting process. Since this kind of manufacturing process require less machining, the unit cost is considerably lower compared to other alternatives.

Aluminum Castings are as Strong as Steel Castings

Despite being weighing very little, aluminum castings features the same strength as that of st eel castings. Thanks to its superior metallurgical properties, aluminum castings exhibit a higher degree of pressure tightness. In fact, their strength advantage is evident over sand castings and other options.

When is Aluminum Casting Applied?

Manufacturers often use aluminum casting when forging or machining of aluminum alloys cannot be employed. This material that comes with a luminous finish is used in producing different commercial and household goods. To give you an idea about when aluminum casting can be used, below we list out some typical applications of cast aluminum parts:

Construction and Architecture

Since aluminum is known for its outstanding conductivity and its light weight that works well for extended lengths of cable runs, copper has now been replaced by aluminum as the base for electrical transmission lines and power grids. Furthermore, architects use aluminum castings for renovations that include ornamental door framings, rooftop corner pieces, and reinforcement pieces.

Aerospace

Since the combination of aluminum castings’ properties including its light weight and strength make them ideal for the development of vehicles that are both strong and light enough to go beyond the earth’s atmosphere, the aerospace industry has been greatly dependent on them. In fact, commercial transport planes are comprised of 80% aluminum castings. Plus, aluminum is extensively used in the space industry for shuttles as well as for various structures at the international space station.

Appliance and Technology

Aluminum castings are also used for refrigeration applications primarily because of its thermal properties and its light weight that allow easy transport.

Renovation and Restoration

In most cases, restoration projects can present unique challenges because they can be quite difficult to source designs that match the metal elements that need to be replaced. It doesn’t matter if the existing casting needs to be directly copied or a new master pattern needs to be carved – aluminum castings will be perfect for duplicating hard-to-find castings that can help you finish the historical restoration with the components that you need.

Want Investment Casting for your Next Project?

If you are interested in using aluminum gravity die casting or aluminum pressure die casting for your next project, contact TCC Casting!

Stainless Steel Investment Casting of Boat Steering Wheel

23/05/202129/07/2021 admin

What is Boat Steering Wheel?

Boat steering wheel is the wheel moves the boat rudder which changes the direction of the vessel. This action is also what a tiller would do. The boat wheel is part of the entire steering system that can contain the pedestal, helm, helm controls, steering cables and other steering system parts. We carry many top-tier and popular brands for boat steering wheels including Schmitt & Ongaro, SeaStar Solutions, Edson, Sea-Dog, Uflex that offer a wide selection of replacement boat steering wheels to fit your boat. As the top leading stainless steel investment casting company, TCC Casting can customize and export boat steering wheels for our customers all over the world.

Stainless Steel Investment Casting of Boat Steering Wheel

Material: Marine Grade 316 Stainless Steel

316 stainless steel is a popular chromium, nickel, molybdenum-bearing stainless steel grade. For its good corrosion resistance to pitting and crevice corrosion in chloride environments, type 316 stainless steel is widely used in marine application, thus it is always referred to as marine grade stainless steel.

Compared with 304 stainless steel, molybdenum(Mo) element is added in 316 cast stainless steel boat steering wheel. Molybdenum(Mo) element can strength the molecular structure of boat steering wheel. Besides, Mechanical properties of 316 stainless steel boat steering wheel are better than that of 304 stainless steel boat steering wheel. This can make the life time of 316 investment cast boat steering wheel longer.

Manufacturing Process: Stainless Steel Investment Casting

Stainless steel investment casting is another name of stainless steel lost wax casting. It refers to make stainless steel components in lost wax investment casting process. TCC Casting is professional on stainless steel investment casting process. Main processes for stainless steel investment casting: wax/foam injection, trimming and welding wax trees, sand shell mould-making, dewax, baking the shell mould, casting, heat treating, shot blasting, inspection and packing.

Same as other marine hardwares, boat steering wheel can be produced by stainless steel investment casting process. Stainless steel investment casting process can control a better dimension accurancy and surface finish for boat steering wheels. Usually, no machining is required. Cast tolerance can reach ISO8062 CT5-CT6. Surface roughness of cast boat steering wheel is between Ra3.2 to Ra6.3. Surface finish of cast boat steering wheel can be shot blasted or mirror polished, which is mainly decided by our customers.

Besides boat steering wheel process, stainless steel investment casting process can also be used to make other marine hardwares, such as bruce boat anchor, boat propeller, boat rail base fittings, marine cross bollard, etc.

TCC Casting quotes and produce such stainless steel boat steering wheel or other products according to drawings or samples from customers. If your have such RFQ’s, please contact us. We will offer you our best prices and services.

Stainless Steel Casting for Bruce Boat Anchor

23/05/202110/07/2021 admin

Bruce type anchors are one of the most popular anchors for marine application and are known for their high holding power and self setting capability. For boaters anchoring in a variety of bottom conditions, including sand, mud, rock, and coral, bruce anchor is the boat anchor we recommend most. It has slightly less holding per pound than similar style anchors such as the Delta/Wing but it generally sets more easily. Each bruce anchor includes a small trip line point at the back of the anchor. While not used by most boaters, it offers the option to attach a secondary line to release the anchor in case there is a danger of the anchor getting snagged. Includes a lifetime warranty against breakage.

Bruce anchors are investment cast in stainless steel and made in a one piece, solid construction with no moving parts, this ensures durability and a long life expectancy. TCC Casting is the professional stainless steel casting manufacturer can supply custom service for bruce anchors in different sizes. With investment casting method and mirror polished surface, we can offer high dimensional accuracy and good surface finish.

Material: 316 Stainless Steel

Stainless Type 316 – often referred to as stainless steel marine hardware. Contains 16% chromium, plus the addition of molybdenum. Molybdenum is what makes, Type 316 ideal for applications around saltwater and other high chloride environments. Learning more on the benefits of using 316 stainless steel castings

Casting Process: Investment Casting

Investment casting, also named as precision casting or lost wax casting, is usually adopted to produce stainless steel casting parts for marine application. Bruce anchor, the most common boat achor, is generally designed and produced by investment casting process.

The investment casting process offers many benefits including cost savings, design freedom, close tolerances, better finishes, savings in machining time, reproducibility, and assembly savings.

TCC Casting can cast stainless steel bruce anchors from drawings or samples. With semi-automatic casting process, both the quality and production effeciency are higher than other foundries in China. The casting tolearance controlled in our foundry can be ISO 8062 CT5-CT6 level.

Surface Finish: Mirror Polishing

After investment casting, the surface of bruce boat anchors is a bit dark and rough.To achieve smooth and shinning surface, cast stainless steel bruce anchor are always mirror polished. Mirror polishing is a hand-polishing process involving several polishing steps, so it is slow but the cost is affordable. TCC Casting can provide mirror polishing service to deliver finished products to our customers.

316 Stainless Steel Investment Casting of Hawse Pipe

23/05/202110/07/2021 admin

A ship’s hawse pipe is the pipe passing through the bow section of a ship that the anchor rode (chain, line, or both) passes through. The main function of the hawse pipe is to guide the chain from deck level to outside the shell plating. The hawse pipe should be constructed to a size large enough to accommodate the smooth running of the chain and to provide secure stowage of the anchor, permitting it to drop freely when released without jamming or risking damage to the hull structure.

It is made from investment casting process in 316 stainless steel for maximum corrosion resistance and durability. The square hawse pipe can be flush mounted or recessed, and is easily installed using fasteners.

316 Stainless Steel Investment Casting of Hawse Pipe

316 Stainless Steel Casting of Hawse Pipe

Material: 316 Stainless Steel

Due to its strength, durability, and longevity, stainless steel is one of the most common investment casting materials for marine industry . The alloy of iron, chromium, and carbon has an improved corrosion resistance over regular steel, which, like most ferrous metals, rusts when exposed to water.

316 stainless steel is more commonly known as “marine grade stainless steel” as its enhanced corrosion-resistance properties make it ideal for use throughout the marine industry. The material you typically find being used in restaurants, commercial kitchens, etc. is 304 stainless steel, or “food grade” stainless steel.

Marine-grade stainless steel takes the inherent benefits of standard stainless steel and improves on them through increased levels of chromium and molybdenum. The addition of these elements provides a greater corrosion resistance than many of the other commercially available grades of stainless steel. This level of corrosion-resistance is absolutely essential for hawse pipe in ship. 316 stainless steel also provides incredibly high yield and tensile strength when compared to its weight, making it a truly ideal material for hawse pipe. In summerize, the benefits of 316 marine grade stainless steel are:

Enhanced corrosion resistance to withstand saltwater
Chemical-resistant
Incredible insulating properties
Durable and hardwearing, yet lightweight
Non-magnetic
High stress-to-rupture strength
Heat-resistant

Why Investment Casting for Stainless Steel Hawse Pipe?

Due to the nature of the process, investment castings can be held to much tighter tolerances than sand castings or forgings. This can be important and can avoid machining or other finishing operations. Investment casting offers near net-shape, thus reducing costly machining time. Investment casting is also capable of more reliable castings with much thinner walls than sand castings. Due to the thinner wall capability, investment castings produce substantially less scrap rates and lighter weight castings. Investment castings, in general, provide a much higher percentage of defect free-castings.

The investment casting or precision casting process is an excellent option for producing dimensionally accurate parts that require superior corrosion resistance for 316 stainless steel hawse pipe. The near net shape that is achieved with the hawse pipe outweigh the costs incurred through the less precise and less efficient process of sand cast. Since many highly corrosion resistant materials are cast on a regular basis, employing investment casting process makes good economic sense.

At TCC Casting, we manufacture thousands of stainless steel investment casting parts each year and have an outstanding track record of doing so in the industries fastest lead times at competitive prices. We also have the ability to provide parts with additional surface treatments such as mirror polishing to enhance corrosion resistance even more and provide parts with superior surface finishes. Our advantages also lie in:

Low cost, precision, long life tooling
Ability to cast intricate features with excellent corrosion resistance
Uniquely-designed quality control system
Affordable pricing
Friendly, knowledgeable, and prompt customer service
Quick and on time delivery

If you have any inquiry on custom hawse pipe or other marine hardwares, pls contact us freely!

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Stainless Steel Casting of Top Cap for Bimini Top

30/04/202129/07/2021 admin

The top cap is the marine boat fitting designed for sailboat and powerboat bimini tops. Together with top slide or deck hinge, it can accept tubes in different diameters. Like all the cast marine boat fittings, the top cap is also made in 316 cast stainless steel.

Stainless Steel Investment Casting Process

When it comes to making complex marine boat fittings with fine details, manufacturers often go for stainless steel casting for several good reasons. Compared to machining or other manufacturing processes, stainless steel investment casting may be more expensive and have a longer production cycle, but its tighter tolerances, smooth as-cast finish and freedom of design also give it an edge over other casting processes. This process is often used to make high strength marine boat parts that require immaculate quality and precision.

Stainless steel investment casting is a labour and skill intensive process that involves many delicate steps (wax mold making, shell making, pouring, cooling etc.). The casting capabilities of different foundries may vary drastically, so it is always recommended to have professional casting engineers to review and QC check the production process.

Mirror Polished Finish

Same as other stainless steel marine boat fittings, the surface finish of top cap is mirror polished after investment casting. Mirror polishing is a surface finish that is smooth enough to provide a reflective surface. Normally, the complete mirror polishing involves at least three polishing processes. To serve our customers better, we have an separate mirror polishing workshop in our foundry with skilled polishing workers.

TCC Casting offers stainless steel investment casting and mirror polishing for all your stainless steel marine needs. Our cast stainless stainless marine boat parts are corrosion resistant and rust proof. Besides top caps, we can also provide stainless steel investment castings for other boat hardwares including cleats, chocks, steering products, rod holders, hatches, deck pipes, etc. Any inquiry on stainless steel casting of marine boat top caps or other products, pls feel free to contact us!

Notes:

If you have limited budget, it is ideal to buy top caps from China foundries, like TCC Casting.
Make sure the supplier can supply polished tops caps, not only castings.
Ask for a sample at least before mass production to check the surface quality.
For custom top caps, remember that the mould cost is charged only once, there is no need to pay again for future orders.
Clearly state your package requirement to avoid any damage during transportation process.