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Casting

Deloro provides four casting processes to produce components from Cobalt, Nickel and Iron based alloys.

Solid components benefit from wear properties that are consistent throughout the component, particularly in shapes and configurations that would be difficult or impossible to protect otherwise. Solid components are produced by: casting, powder metallurgy or wrought material processes. With our in-house, fully equipped and staffed machine shops, we are able to finish machine solid components to your surface and dimensional requirements.

Air Investment Casting

Precision air-poured investment casting is ideal for intricately shaped components. The lost wax, ceramic shell process produces high near-net-shape components with good-as-cast surface finishes, minimizing machining requirements. Alloys are melted in high-frequency induction furnaces, offering complete flexibility and metallurgical dependability. A wide range of cobalt, nickel and stainless steel alloys can be poured in our investment foundries. All castings poured can be produced to print in our well-equipped machine shops.

This technology is avalable at Deloro Wear Solutions GmbH and Deloro Microfusione S.r.l.

 

Vacuum Investment Casting

Similar to air-poured investment casting, this process utilizes a vacuum to remove air from the ceramic mold, allowing the pressure differential to fill the mold while eliminating oxidation during the pouring process. This is particularly important when alloys include elements such as aluminum or titanium. Vacuum Investment Casting is used most often to pour aerospace and industrial gas turbine components.

This technology is exclusively available at Deloro Microfusione S.r.l.

The sand casting process is used typically for larger parts and for small quantities of parts. Sand casting is capable of making fairly complex shapes using relatively inexpensive wood patterns. Sand, containing a natural or synthetic binder, is packed around a wood pattern, the sand is then tamped down to provide the two-part mold with adequate strength. The pattern is then removed, leaving a negative form in the mold. Cavities can be produced in the sand casting by inlaying one or more cores in the mold. The two halves of the mold are clamped together ready for casting. Our sand and face coat systems have been optimized to give superior surfaces for corrosion resistant alloys. 

A wide range of cobalt alloys, nickel alloys and stainless steel alloys can be poured in our modern Sand Foundry. All castings produced can be finished to print in our Machine Shop.

Typical applications

Sand casting is best for large components with thick cross sections. This process is capable of making fairly complex shapes using relatively inexpensive wood patterns. If your component meets one or more of the following basic criteria, sand casting could be the correct process selection.

  • Low to medium volume requirements
  • Simple to medium part complexity
  • Component has thick cross section

The steel or aluminum pattern and runner are mounted on a flat steel plate, which is heated to a temperature that will cure the sand/resin mixture. The shell is stripped off and clamped against a flat or similarly moulded shell to form the mould cavity for the molten alloy, thus reproducing the pattern. For hollow components separately moulded cores are placed between the two halves of the mould before closing.

Complex moulds with integrated cores can be produced by the resin shell moulding process, allowing the production of parts with complex geometries. The resin shell process features comparatively good near-net-shape accuracies and good surface quality. Resin coated zircon sand is poured on to a heated pattern plate; the resin is cured and one half of a mould is thus formed. Two halves of a mould are then bonded together, ready for casting. 

Typical applications

Resin shell casting is an economical approach for medium to large volume production of relatively simple shapes. This process achieves a more refined microstructure and higher hardness levels than regular sand castings making it advantageous for cutting tools and knives. If your component meets one or more of the following basic criteria, resin shell casting could be the correct process selection.

  • Medium to large volume requirements
  • Relatively simple shapes
  • Require refined microstructure
  • Require higher hardness

Spin or Centrifugal Casting is ideal for high quality cylindrical components. As the name implies, centrifugal force is employed to exert pressure on the molten metal as it is poured into a spinning mould resulting in a dense part with a fine uniform grain structure. The wall thickness of the part is determined by the amount of poured metal. The centrifugal force presses the molten metal against the inner wall of the mould, densifying the metal and thus reducing shrinkage porosity and gas related defects. The integrity and wear resistance of these structures make them exceptional where there is frictional wear. Centrifugal castings are supplied in a semi or finish machined condition.

Typical applications

If your component meets one or more of the following basic criteria, centrifugal casting could be the correct process selection:

  • Your component is cylindrical in shape
  • Uniform grain structure required
  • Fine grain structure required

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