What is a Casting?  

Metalcasting is a process in which molten or liquid metal is poured into a mold made of sand, metal or ceramic, to form geometrically complex parts. The most common metals include iron, aluminum, magnesium, zinc, steel and copper-based alloys. Metal castings are used in cars, trucks, planes, trains, mining and construction equipment, oil wells, kitchen appliances, pipes, toys, space shuttle, wind turbines, nuclear plants, tanks, bombs, and more. (American Foundry Society) Look around- you will always find castings nearby! 

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What you didn’t know about castings:

• Of those that signed the Declaration of Independence, 7 were metalcasters. 
• 90% of all manufactured goods contain metal castings. 
• The U.S. is the global leader in casting applications and second in production. 
• You are rarely more than 10 ft. from a metal casting in the United States.

Delivery:

On time is important. Ensure you know the on-time performance of your supplier. At MMP, we are proud of our record and gladly share it. Your business is important, and we know it! 

Service:

There are many areas that are service, even in the foundry world. For example, look for a supplier who gives ‘front of the line’ service if your team finds a problem with a delivered item or service. A supplier who offers shorter lead times through a premium program can keep your line moving when you might have given up hope! 

Quality:

Things are different when a metallurgist owns and operates the plant. No matter what standard of quality you choose, we will not only meet or exceed it, we will put you at the front of the line.

A Buyer asks: “How can I reduce parts count AND cost?”

Would your boss be impressed if you were reduce both the parts count and the cost for a component? Almost every manufacturing business has parts built up using welding. These ‘weldments’ are labor intensive. Plus each of the component’s pieces must be carried in inventory or cut from plate or pipe- both labor intensive. Just as integrated circuits or ‘chips’ decreased the parts count, lowered the cost, and improved the reliability of electronics, a casting may be the answer to earn these same benefits. Download a free “Weldment Evaluation” certificate on our website.

Price

The cost of castings and services is important as one component of the Total Cost of Ownership. When you partner with MMP, we work side by side to reduce the TCO, which saves more money than just buying cheap castings.

Evaluating Risk when sourcing castings, finishing or heat treating

6 simple questions to ask any casting supplier

1. What is the debt load vs revenue?

The more debt, the higher the possibility of risk with your quote. Foundries have been closing at a rate as high

as 50 a year in the US and you don’t want your castings, tooling, and drawings lost in bankruptcy

proceedings…

2. Is a metallurgist on staff?

A Metallurgist is a highly trained expert who uses his specialized knowledge of the physical and chemical

properties of metals to your advantage. They keep costs lower, and deliveries on time, because they identify

potential issues that would cause high scrap rates BEFORE they occur. When there are problems in any

foundry, they call in an outside metallurgist. If one is on staff, it reduces your risk.

3. What is the on-time delivery rate for the past 12 months?

You need your parts delivered on time. Why not ask what their on-time delivery percentage is? There is no

reason it should ever be below 95%. But things happen, like weather delays, equipment failures, or catastrophic

events. If you don’t ask, it’s your fault when your quote isn’t delivered on time…

4. What is the scrap rate using “retail value of scrapped parts divided by revenue”?

Not all castings are perfect. With over variables, that’s to be expected. But the scrap rate is a simple

measure of how well the foundry is doing. There are many ways to measure scrap, but using “retail value

If you are looking for more details, kindly visit brass casting process.

divided by revenue” is the most logical way to determine the scrap rate. While some foundries will tell you

they re-use the scrap, or it varies from product to product and pour to pour (both may be true), this simple

formula tells the real impact on the business. Higher scrap rates may indicate higher risk.

4. What percentage does each of the top 5 clients contribute to Gross Revenue?

If a single customer contributes more than 10-12% to a foundry’s revenue, that customer could leave and bring

down the whole operation. Ask for the percentage that the top 5 customers contribute to gross revenue.

5. What percentage does each Market Sector contribute to Gross Revenue?

A foundry with more than 15% of their production in a specific area, say wind energy, may have problems

when there is a downturn in the wind energy sector. Since most foundries are small businesses, you need to

know the risk to your quote and delivery time if there is a downturn in another industry. Asking the Market

Percent of Gross is a numerical analysis to judge the risk of one economic sector impacting your order.

6. Does the foundry just do casting, or do they offer heat treating, finishing services, and an

engineering support capability?

A diversified business has more strength and stability over the long run. Plus, a well run foundry will accept

other castings for finishing or heat treating, giving added value versus in-house. Risk is reduced when there is a

diversification of services as well as capabilities.

Metal Casting Buying 101: A Comprehensive Guide for All Your Needs

For many industries, the task of purchasing components made of cast aluminum is essential. At Boose Aluminum Foundry, we pride ourselves on being an industry-leading foundry specializing in providing top-quality aluminum sand castings for many different applications.

With expertise in the sand casting process, we ensure our customers receive the ideal solution tailored to their needs. This guide aims to provide valuable insights into the casting process, helping you make informed decisions when sourcing castings.

How Do You Select the Right Casting Method?

To select the proper casting method, consider the desired material properties, the part’s complexity, production volume, and budget constraints. Then, evaluate various casting techniques, like sand casting, permanent mold, investment casting, and die casting, to determine which method best aligns with your project requirements and goals. When choosing a casting method, consider the following factors:

• Material compatibility: Ensure that the casting method suits the specific material you plan to use.
• Production volume: Some casting methods are more cost-effective for low production volumes, while others are better suited for higher volumes.
• Complexity and detail: Certain casting methods can produce more intricate and detailed parts.
• Surface finish and dimensional accuracy: The casting method will affect your cast components’ final appearance and accuracy.

Casting Methods

Several types of castings are available in the market, each with unique properties and applications. Some common types include:

1. Sand casting: This is the most widely used casting method, where a sand mold is created to form the desired shape. It is suitable for ferrous and non-ferrous metals. With relatively low upfront foundry tooling costs, it is most cost-effective for low, medium, and occasionally high production volumes.
2. Permanent mold casting: This method uses a reusable mold made of metal, allowing for better dimensional accuracy and surface finish than sand casting. It is suitable for non-ferrous metals like aluminum and magnesium. With medium to high upfront foundry tooling costs, it is most cost-effective for medium to high production volumes.
3. Investment casting: Also known as lost-wax casting, this process involves creating a wax pattern, coating it with a ceramic material, and then melting the wax to create a ceramic mold. It offers high precision and is ideal for complex shapes and intricate details not possible with sand casting. It is suitable for ferrous and non-ferrous metals. With relatively low upfront foundry tooling costs, it is most cost-effective for low, medium, and occasionally high production volumes.
4. Die casting: In this method, molten metal is forced into a reusable die under high pressure. Die casting is suitable for non-ferrous metals and produces parts with excellent dimensional accuracy and surface finish. With relatively high upfront foundry tooling costs, it is most cost-effective for high production volumes.

Aluminum Metal Casting

Compared to ferrous materials like cast iron and carbon steel, aluminum boasts a lightweight nature while maintaining impressive strength, making it ideal for various applications. Furthermore, aluminum castings provide excellent heat dissipation and corrosion resistance, greatly contributing to the overall casting quality and functionality.

Aluminum’s adaptability to various casting processes enables manufacturers to determine the most efficient method for their specific needs, ultimately leading to cost savings for both the supplier and customer. Additionally, aluminum alloys offer a wide selection of material properties, ensuring that engineers and purchasers can find the perfect alloy for their project requirements.

How Can You Find a Reliable Casting Supplier?

It’s crucial to source castings from a reliable supplier to ensure consistent quality and timely delivery. Here are some tips for selecting a casting supplier:

• Research: Conduct thorough research on potential suppliers, including checking their reputation, certifications, and experience in your industry.
• Request quotes: Depending on your circumstances, it might be helpful to obtain multiple quotes from different suppliers to compare prices, lead times, and other terms.
• Ask for samples: Request samples or images of the supplier’s previous work to evaluate their quality and craftsmanship.
• Communication: Establish clear communication channels with your supplier to ensure smooth collaboration and timely updates on production progress.

Quality Control and Inspection

Implementing strict quality control measures and conducting regular inspections are critical to ensure the castings meet your specifications. Some common inspection methods include:

• Visual inspection: Check for surface defects, such as porosity, cracks, and inclusions.
• Dimensional inspection: Verify that the castings meet the specified dimensional tolerances using measuring tools like calipers, micrometers, laser scanners, and coordinate measuring machines (CMMs).
• Non-destructive testing (NDT): Techniques like radiography, ultrasonic testing, liquid penetrant inspection, and magnetic particle inspection can detect internal defects without damaging the casting.
• Destructive testing: Tensile, impact, and hardness tests can provide valuable information about the casting’s mechanical properties and performance under stress.

By following this guide, you can make informed decisions when buying castings, ensuring you select the suitable method, supplier, and quality control measures for your specific needs.

Want to Talk to The Experts on Casting Buying?

When you’re ready to purchase casting materials, the experts at Boose Aluminum can help. We deliver lightweight, durable, and corrosion-resistant cast parts by leveraging aluminum’s excellent mechanical properties and cost savings. Our commitment to casting quality and customer satisfaction makes us a preferred choice for casting buyers across numerous sectors. Get in touch with us today to get started!

Contact us to discuss your requirements of shell mold casting. Our experienced sales team can help you identify the options that best suit your needs.

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