Sand casting is used to make large parts (typically iron, but also bronze, brass, aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or synthetic). Sand castings generally have a rough surface, sometimes with surface impurities and surface variations.
Die casting is production of castings from a reusable mold or die. The die contains an impression of the casting together with its running, feeding, and venting systems. The die is capable of a regular cycle and of quickly dissipating the heat of the metal poured into it.
Permanent mold casting involves molten metal being poured into cast iron molds, and coated with a ceramic mold wash. Cores can be metal, sand, sand shell, or other materials. When completed, the molds are opened and the castings are ejected.
Investment casting patterns are molded by the injection of a special wax into a metal die. The patterns are assembled into a cluster around a wax runner system. The 'tree' of patterns is then coated with 8-10 layers of a refractory material. The assembly is heated to remove the wax. The hot mold is cast and when cool, the mold material is removed by impact, vibration, grit blasting, high pressure water blasting, or chemical dissolution leaves the castings, which are then removed from the runner system.
In centrifugal casting, a permanent mold is rotated about its axis at high speeds as the molten metal is poured. The molten metal is centrifugally thrown towards the inside mold wall, where it solidifies. The casting is usually a fine grain casting with a very fine-grained outer diameter, which is resistant to atmospheric corrosion. The inside diameter has more impurities and inclusions, which can be machined away.
Lost foam casting (LFC) is a type of metal casting process that uses foam patterns to produce castings. Lost foam casting uses a cavity-less mold with the pattern remaining in the mold during metal pouring. The foam pattern is replaced by molten metal, producing the casting.
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Design assistance can assist with concepts, manufacturing costs, manufacturing techniques, and material considerations. The supplier may also be able to assist in upgrading or redesigning, re-evaluating or modernizing existing products to increase performance and/or reduce manufacturing costs. Some suppliers offer material sourcing and CAD modeling as well.
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Heat treating is a broad category of processes used to treat metals (e.g., annealing, passivation, hardening, etc.). Stress relieving is used to relieve residual stresses imposed during the casting process.
Finishing and surface treatment services pretreat or finish the surfaces of manufactured components to meet roughness or surface condition requirements.
Other unlisted, specialized, or proprietary secondary operations.
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Ferrous metals refer to a broad category of metals where iron is the primary constituent. Ferrous metals include carbon and cold-rolled steels, stainless steel, etc.
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Nonferrous metals and metal alloys include brass, copper, aluminum, and nickel and their alloys. Bronze, Inconel®, Monel®, and other specialty alloys fall into this category.
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Aluminum and aluminum alloys are lightweight, non-ferrous metals with good corrosion resistance, ductility, and strength. Aluminum is relatively easy to fabricate by forming, machining, or welding. It is a good electrical and thermal conductor. Aluminum is also useful as an alloying element in steel and titanium alloys. Aluminum alloys are versatile metals with applications in almost every industrial and commercial segment.
Cobalt and cobalt alloys are non-ferrous magnetic alloys with high strength and toughness, excellent corrosion and oxidation resistance, and high temperature strength. Cobalt can also be magnetized. Cobalt's properties result in the use of cobalt alloys in jet engine super-alloy components, prosthetic devices, magnets, and cutting tool binders. Cobalt is a useful alloying element in tool, maraging, and other alloy steels.
Copper and copper alloys are non-ferrous metals with excellent electrical and thermal conductivity as well as good corrosion resistance, ductility, and strength. Copper alloys are relatively easy to fabricate by forming, casting, or machining. Pure copper is more difficult to weld, cast, or machine. Brass, tin bronze, leaded brass, beryllium copper, and zirconium copper are examples of copper alloys. Copper is also useful as an alloying element in aluminum alloys and powder metal-based iron alloys. Copper is a versatile metal with applications in many industrial and commercial segments. Copper's high electrical conductivity (100% IACS) make it extremely useful in electrical and electronic applications.
Cast iron is an iron alloy with high amounts of carbon. This category includes ductile iron, gray iron, and white cast iron grades. Differences in grades are due to variations in composition and processing.
Magnesium and magnesium alloys are non-ferrous metals with low density (relatively high strength to weight ratio), good ductility, moderate strength, and good corrosion resistance. Magnesium and magnesium alloys are used in a variety of industries as well as in aircraft, marine, and power tool applications.
Nickel is a constituent of many alloys; common nickel alloys include: Hastelloy® alloys, which exemplify high resistance to uniform attack and localized corrosion resistance; Incoloy® alloys, which combine good strength and excellent resistance to oxidation and carbonization in high temperatures and many aqueous environments; and Monel® alloys, which have high strength and resistance to a range of corrosive media.
Hastelloy is a registered trademark of Haynes International. Incoloy and Monel are registered trademarks of Special Metals Corporation Special Metals Corporation.
Refractory metals and alloys are metals with melting points above ~1750 C (~ 32000 F). They are used in high temperature, structural, electrical, and other specialty applications.
Reactive metals combine readily with oxygen at elevated temperatures to form very stable oxides. Titanium, zirconium, and beryllium are considered reactive metals. Finely divided reactive metals can react explosively with oxygen and are often added to rocket fuels or combustible mixtures. A highly stable oxide film formed on the alloy surface provides protection against further oxidization or corrosion at low to moderate temperatures. Reactive metals can become embrittled if there is too much interstitial absorption of oxygen, hydrogen, and nitrogen into the lattice.
Alloy steels are ferrous alloys based on iron, carbon, and alloying elements such as chromium, molybdenum, vanadium, and nickel. Alloy steels include hardenable high alloy steels, high strength low alloy steels, maraging steels, and other specialty steel alloys. Steel alloys are used in a wide variety of applications in almost every industrial segment. Low alloy steels can be fabricated easily by machining, forming, casting, and welding.
Titanium and titanium alloys are non-ferrous metals with excellent corrosion resistance, good fatigue properties, and a high strength-to-weight ratio. Titanium and titanium alloys are commonly used for aircraft or air frame parts, jet engine super-alloy components, corrosion resistant chemical process equipment (valves, piping, and pumps), prostheses or medical devices, and marine equipment.
Lead, tin, and white metals are low melting non-ferrous metals and alloys. They are used as solders, battery electrodes, bearing liners, decorative products, and coatings. Indium, tin, lead, and antimony are used to manufacture semiconductors.
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ISO 9001:2000 sets out the requirements for a company's quality management systems. These standards range from manufacturing to services including design and development, production, installation, and servicing.
ISO 13485:2003 specifies quality management system (QMS) requirements for organizations that need to demonstrate their ability to provide medical devices and related services that consistently meet applicable customer and regulatory requirements. ISO 13485:2003 contains specific requirements for medical devices and excludes non-applicable requirements from ISO 9001. Consequently, an organization with a QMS that conforms to ISO 13485:2003 cannot claim to conformity to ISO 9001 unless the QMS meets all of ISO 9001’s requirements.
ISO 14001 specifies the actual requirements for an environmental management system. It applies to those environmental aspects where the organization has control or influence. ISO 14001 was first published in 1996 and is the only ISO 14000 standard against which it is currently possible to be certified by an external certification authority.
QS-9000 is the set of standards based on ISO 9001 with particular application to the automotive industry; standards are defined and maintained by major automotive manufacturers. Standards concern part fabrication and quality in areas such as materials, heat treatment, finishing, and production processes.
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Companies are located in the Northeast United States; namely Connecticut, Maine, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island and Vermont.
Companies are located in the Southern United States; namely Alabama, Arkansas, Delaware, Florida, Georgia, Kentucky, Louisiana, Maryland, Mississippi, Missouri, North Carolina, Oklahoma, South Carolina, Tennessee, Texas, Virginia, Washington D.C., and West Virginia.
Companies are located in the Midwest United States; namely Illinois, Indiana, Iowa, Kansas, Michigan, Minnesota, Nebraska, North Dakota, Ohio, South Dakota and Wisconsin.
Companies have facilities in South American countries such as Argentina, Brazil, or Chile; or in Central American countries such as Costa Rica, Honduras, Panama, etc.
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