Enclosures

Metal castings cover wide range of options

5th March 2021
Mick Elliott

Advanced new metal casting capabilities from AMFAS International are now available at distributor New Yorker Electronics.

These processes include die casting, investment casting and sand casting in stainless steel, carbon steel, aluminum, copper/brass and super alloys (Inconel). 

Die Casting Die Casting, a process similar to injection moulding, uses a die or mould to inject molten metal into the tool which then cools until the part can be removed and handled without distortion.

This is typically used for high-volume applications.

The mould die is commonly made from high performance tool steels, and its lifespan consists of millions of shots before any deterioration of the steel tool due to high temperatures and cooling. AMFAS often refurbishes sections of the tool to save customers the expense of a new tool. 

Through AMFAS International, New Yorker Electronics offers hot and cold chamber and vacuum assist casting and produce parts to 50 pounds with aluminum alloys, zinc and magnesium. Equipment includes 280T to 2000T high pressure die casting machines, robotic material handling and centralised furnace and dumping furnaces. 

Investment Casting Although labour intensive, investment casting delivers high precision and repeatability.

Investment casting employs a shell made of ceramic, plaster, or plastic that is formed around a wax or styrene pattern. The wax pattern is melted and removed in a furnace and metal is poured into the shell to create the casting. 

Investment casting can produce parts in almost any metal with features that cannot be easily machined or die cast.

New Yorker Electronics and AMFAS say they can advise on the best casting option given the material, part geometry, volume and other considerations.

Part sizes range from 1oz to 150lbs. Materials used include stainless steel, carbon steel alloys, aluminum alloys, super alloys (Inconel), copper & brass alloys and iron. 

Sand Casting In the case of sandcasting, sand acts as the mould die. A pattern of the actual part is made typically from wood or metal with two halves representing the needed part.

These patterns are then used to make a temporary die made of sand. The two halves of the sand mould are joined together and the molten metal is poured into the sand mould. 

Within a few minutes the metal cools and the sand mould is removed using vibration and mechanical means. With AMFAS International, the sand is then pulverised, sifted and reused.  

Advantages of sand casting are that it is relatively inexpensive, especially for lower volumes.

Very large components are possible, and ferrous and non-ferrous materials are possible with nearly any alloy.

AMFAS uses stainless steel, carbon steel alloys, aluminum alloys, copper & brass alloys and iron for sand casting.

Die Casting Features:

  • Machines up to 2000 tons
  • Tolerances: As cast ± .005"; 0.5 degree draft
  • Minimum wall thickness: Zn & Mg: .04", AL: .08"

Investment Casting Features:

  • Tolerances: As cast ± .010" up to 2", ±.005" each additional 1"; 0 degree draft

Sand Casting Features:

  • Part size from 1oz to 150lbs

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