State-of-the-art casting technology for the best results
Sand Casting
In sand casting, a tool is first created according to the given drawings. The tool is then used for modelling a sand mould, usually divided in top and bottom part. To produce hollow bodies, it is required to insert cores, they are also made by sand. The partitions (usually in one box) are combined together, and the cavity is filled with the molten material. The pattern is designed slightly larger to compensate the shrinkage during cooling process. Depending on material grade shrinkage occurs 0.5-2.5%.
The entry and exit channels are very important (feeder and raiser). The liquid metal is poured into the sand mould via feeders. Through the raiser gases and excess material can escape. This is necessary to avoid casting errors. After the cast body has solidified, the sand is removed, and the part can be processed further.
Material grades: carbon steel and stainless steel, iron grades and non-ferrous metals
Investment Casting
Investment casting is mostly used to produce smaller cast parts. Investment casting has a better contour than sand casting and has higher dimensional accuracy and surface quality. That reduces machining time.
With special tools, wax pieces are produced that accurately represent the components to be cast (plus the calculated vibration). These wax figures are made in several layers with sand and binding agent, coated and dried in a precisely specified manner. A solid ceramic form is created. The wax is then melted out of the ceramic at high temperatures. The cast is made in the hollow ceramic moulds. After cooling, the ceramic moulds are removed, and the cast is further processed.
Material grades: carbon steel and stainless steel
Gravity Die Casting
The permanent mould casting process is a casting process in which the liquid melt is poured into a mould through an opening. The cavity of the mould corresponds to the negative form of the casting. The gravity of the melt is sufficient to fill the cavity. Aluminium is usually cast, but steel is also cast. A low-pore casting with a good surface is achieved with this process.
Material grades: carbon steel and stainless steel, iron grades and non-ferrous metals
Pressure Die Casting
Die casting is a process for series or mass production. Alloys with a low melting point are usually used for this purpose, e.g., B. non-ferrous metals.
The casting process takes place under high pressure of approx. 10 to 200 MPa and with a very high mould filling speed. The die casting mould is a permanent tool suitable for very large quantities.
Material grades: carbon steel and stainless steel, iron grades and non-ferrous metals
Material Grades: Aluminium in different alloys
Forging/ Forming Technology
During forging, a material is heated and shaped by pressure. In general, there are open-die forging and die forging. In die forging, a tool/die is used to be able to produce difficult contours. Because of the additional costs for dies, this process is usually only used for larger quantities.
Material grades: carbon steel and stainless steel, and non-ferrous metals
Machining
To achieve more precise dimensions and surfaces, casted and forged parts are usually also machined. Depending on the component, requirements and quantities, a wide variety of methods and machines are used.
Operations: Turning, Milling, Drilling, planning, grinding, reaming and many more.
Conventional machines are mostly used for smaller quantities and less complex components. CNC machines are used for larger quantities. Complex parts with challenging geometrical tolerances are manufactured on machining centres.
