Cost Saving Castings and Shafts
If you’re ready to re-source your current machined castings and shafts from China, Century Fasteners has high quality sourcing in Taiwan.
1. Investment Castings – Advantages
The investment casting process offers many benefits including cost savings, design freedom, close tolerances, better finishes, shorter machining time, reproducibility, and assembly savings.
Low Initial Tooling Costs:
Initial tooling costs averaged over the parts produced are often less than other manufacturing tooling costs.
Elimination of Material Waste:
Investment castings are essentially cast to size, thus decreasing the amount of machining required.
Design Flexibility and Capability:
Infinite choice of alloys and design flexibility for internal and external configurations is seen as a plus.
There are no draft requirements in the investment casting process.
The process gives a reliable and consistent product order to order.
Consistently producing close tolerances over other processes, is seen as an advantage.
Surface Finish Improvement:
A surface finish of about 125 RMS is common for an investment casting.
If you need a single piece component to reduce assembly and reassembly time, if you want to eliminate the cost of fabrication and reduce the use of welding, or if you wish to use a casting to reduce machining time, an investment casting would be a wise decision affecting your bottom line profits.
2. Aluminum Castings – Advantages
Aluminum alloys are used in die casting more extensively than alloys of any other base metal. Die cast items made of aluminum are lightweight and have high operating temperature tolerances when compared to other items made with standard die casting alloys. Aluminum alloys have outstanding strength and rigidity properties, and good corrosion resistance and heat dissipation. Aluminum die castings are produced for an array of everyday products including kitchen implements, streetlamp housings, medical equipment, small engine housings, and automotive, marine, and aircraft hardware.
Aluminum is light and its density is only one third that of steel.
Highest operating temperatures.
Aluminum is resistant to weather, common atmospheric gases, and a wide range of liquids.
Aluminum has a high reflectivity, therefore, finds more decorative uses.
Aluminum alloys can equal or even exceed the strength of normal construction steel.
Aluminum has high elasticity, which is an advantage in structures under shock loads.
Aluminum keeps its toughness down to very low temperatures, without becoming brittle like carbon steels.
Aluminum conducts electricity and heat nearly as well as copper.
Excellent EMI shielding properties.
3. Sand Castings – Advantages
Sand casting’s main advantages as a casting process include relatively inexpensive production costs, the ability to fabricate large components, a capacity for casting both ferrous and non-ferrous materials and a low cost for post-casting tooling.
Nearly Any Alloy:
Sand castings can be readily produced in nearly any ferrous or non-ferrous alloy. Some other casting processes will melt and pour super-alloys in vacuum, but that is not typically done as a sand casting. Some materials cannot be “worked”, and must be produced as a casting.
Low Tooling Cost:
The relatively low cost of tooling makes sand casting a process of choice for lower volume needs. Patterns do wear so the material selected for the pattern (typically wood, plastic, or metal) will depend on the expected usage quantity of the part being produced. Though not necessarily cheaper in the short run, the use of machined (or “patternless”) molds may be a cost effective option for components with expected lower usage over a longer period of time.
Versatile – Size, Weight, and Shape:
Sand castings can be produced in weights from ounces to 200+ tons. Through the use of cores, internal structures can be cast in place. Shaped parts rely mainly on the imagination of the designer. Most sand castings, however, will need at least some machined surfaces, either because of innate tolerance limits of the process, or the need to mate with other components.
Because the tooling cost can be minimal, sand casting may be appropriate for a single piece run. Alternatively, there are automotive components that are produced using this process, so it may also be used in high volume applications. Other elements of design and tolerance are often more important than quantity when selecting this as the preferred casting process.
The casting process itself may be quicker than some others, like investment casting, but it is important to consider the post-casting processes like machining that may be required when computing total lead times.
4. Shafts and Gears
Century Fasteners can work with our Taiwan source to produce high quality Shafts and Gears to meet your requirements. We can supply Shafts and Gears for various industries including Medical, Industrial, Commercial, Automotive and several others.
5. We utilize 5-Axis Machining
CNC (Computer Numerical Control) machining refers to the process of removing material with high-speed precision machines that make use of a wide range of cutting tools. 5-axis machining refers to a machines ability to move a tool or a part in five different axes simultaneously. Basic machining operates on three primary axes, X,Y and Z; however, a 5-axis CNC machining tool can rotate two additional axes, A and B, which give the cutting tool a multi-directional approach.