Construction

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May 28, 2025

Construction

Precision casting, also known as investment casting or lost wax casting, is a sophisticated manufacturing process that offers numerous advantages over other casting methods. This process involves the use of a wax model, which is coated with a ceramic shell and then melted away to leave a hollow mold. The mold is then filled with molten metal to create the desired component.


Advantages:


  • Design Flexibility - Precision casting allows for the creation of complex shapes and intricate details that cannot be achieved with traditional casting methods.

  • High Accuracy and Consistency - The tight tolerances and precision of the casting process ensure that each component is consistent and accurate, making it perfect for applications that require tight fitting parts.

  • High-Quality Surface Finish - The process provides a high-quality surface finish that requires little to no additional finishing work, reducing production time and cost.

  • Wide Range of Material Choices - Precision casting can be used with a wide range of materials, including stainless steel, carbon steel, aluminum, and brass.

  • Cost-Effective for Small to Medium Production Runs - The setup costs for precision casting are relatively low, making it a cost-effective solution for small to medium production runs.


Disadvantages:


  • Higher Costs for Large Production Runs - While precision casting is cost-effective for small to medium production runs, it becomes relatively expensive for large production runs.

  • Longer Lead Times - Precision casting requires more time for setup and production than other casting methods, leading to longer lead times.

  • Not Suitable for Large Components - Precision casting is not suitable for large components.


Overall, precision casting is a highly effective and reliable manufacturing process that offers numerous advantages. While it may not be suitable for all applications, it is an excellent choice for many industries, including aerospace, automotive, and medical.




QFCMMaterial Testing Procedure
ItemFoot Support - New Design
Issue DateRev 4, 15 March 2008
Press TestLoad TestNDT
1. Across the slot.
35mm gauge length.
2. Across the clevis.
55mm gauge length.
Material GradeZG35, with 0.30 - 0.50% Nickel. Annealed.

We will test analysis here every batch and batch will get 

rejected if Nickel is low. No penalty for Ni > 0.5%.
Batch Numbering2000 max. - we order in batches of 900 - 1800.
Press Test - Incoming 1 in 100. Use visual rejects and foundry rejects.

Clevis should touch without cracking.
Hardness - IncomingAt cut section of slot. Range to be set by foundry.

Too soft - no distortion test may fail.
Final TestingFirst do the load test and then do the press test.
Test Qty1 in 150 nos = 3 per crate.
Clevis BoltUse only gr 12.9 x 5/8 inch special bolts & tighten on the clevis.
Slot BoltUse 1 in 3 of the original bolts and 2 in 3 normal bolts.

Regular testing - Gr 12.9 bolt with a 40/45 OD x 8 thick washer.

For each result report the bolt used.
No Distortion TestIncrease the load to 55KN in 90 seconds, hold for 1 minute,
With original bolt onlyunload and measure the gauge marks.

There should be no distortion.
Load Test Load to 110KN, hold for 1 minute and then unload.

There should be no cracking or failure.

The washer should not pull through i.e the casting should not 

bend too much. This will happen if it is too soft.
Press TestPress the clevis on ONE side till it touches the lower clevis.

There should be no cracks > 10mm.





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