Niagara Investment Castings

In this month's article, we discuss the solidification modelling process from start to finish. This modelling process is a 3D technology intended to graphically demonstrate where the software “predicts” shrinkage-type defects will likely occur in the final cast component. 1. Our engineers generate designs for gating and use the software to validate the designs. The process for the first article sampling then begins. 2. Then, our engineering team will run a “casting only” or “bare” solidification which will identify the areas of risk in the part. This will assist in the design of the gating, the metal delivery system, and any other critical design features of the feeding system. To read more about the other steps to this fascinating process, see: https://lnkd.in/g9iSCVfs

There are many advantages that designers should take into account when considering the benefits of a superior surface quality when specifying investment castings. These include : - Dimensional Accuracy - Reduced Machine Stock Required - Design Challenges Can be Eliminated - Additional Surface Enhancements For more details on each of these factors, read this months article here: https://bit.ly/4eX2Pv3

The key difference between investment casting and other casting techniques can be attributed to the quality of the wax pattern, and the characteristics of the seamless ceramic mold formed around the pattern. The wax patterns are formed by injected melted wax into an extremely smooth and highly polished aluminum die. This allows for the wax pattern to possess the same smooth surface as the tooling. The surface finish of the investment casting is due to the ability to transfer the smooth surface of the wax to the casting. To learn more about this, see this month's article: https://bit.ly/4eX2Pv3

Tool steels are exceptionally hard, tough, or wear-resistant alloys. Their properties come from both their chemistry and the subsequent heat treatments applied after casting. As their name intimates, these steels are capable of cutting, drilling, punching, hammering, and more. Tool steels are selected for a combination of the properties required to meet their application. There are a group of the more commonly investment cast tool steel alloys which form the bulk of the alloys that are cast at Niagara Investment Castings. These alloys allow our clients to select the closest match to meet most every demanding application they require. For a detailed list of all of these alloys and their descriptions, see: https://bit.ly/48j34yS

In this month's article, we answer: "Can Tool Steels Be Investment Cast?" Tool steels consist of carbon and alloy steels typically used for investment casting components for special applications where the more common steels would fail. These alloys are generally called tool steels because of their high hardness, wear resistance and abrasion resistance. While highly useful for these purposes, one key characteristic of all of them is that they do not provide corrosion resistance, which should be taken into consideration. Tool steels include several different groups of alloys, each providing different levels of strength, surface hardness, toughness, working temperature and shock resistance. To learn more about what we offer or for more information on this topic, see our site: https://bit.ly/48j34yS

Placing an object into a liquid media, and a portion of that liquid remaining on the surface of the object once removed from the media is the process called “investing." As a simple example, placing your arm into a bucket of water and pulling it out leaves your arm wet. You have carried out the investing process by some of the liquid sticking to, and remaining on, your skin. In the investment casting process, the disposable patterns are dipped into the tank of ceramic slurry, and on the initial dip, a thin layer of the liquid ceramic remains on the surface of the pattern. It is dusted with fine sand and allowed to dry to a solid ceramic layer. Following this drying, subsequent investing dips are performed, with the ceramic now adhering to the previously applied layer, until a “shell” is formed that is between ¼ to 3/8” thick. This shell is now ready to have the pattern removed via either steam autoclave or burning it out and firing the green ceramic to form a stronger bond. This fired ceramic is strong enough to withstand the high temperature of the molten metal that will be poured into it. To learn more about the meaning behind the name, see: https://bit.ly/4gvQdx5

The preferred and most cost-effective method of using ceramics for casting is investment casting. This method uses a dipping technique to apply "layers" of the liquid ceramic slurry and loose grains of refractory sand. This layer is allowed to dry, and the process is repeated several times to build a suitably strong shell around the patterns. It is this dipping technique that gave this process the name investment casting. To learn more about the basics of investment casting, read this month's article: https://bit.ly/4gvQdx5

There are many times when non-destructive testing is required by the customer, to ensure either batch conformance, or individual casting certifications, to their specific standard. Examples of industries which rely on our providing certified NDT results of our castings include: - Nuclear Power Industry - High-Pressure Pumps and Valves - Military applications such as Submarines, Ships, and Armoured Vehicles - Aerospace - Oil and Gas Equipment - Chemical Processing Equipment To learn more about non-destructive testing, read our blog: https://lnkd.in/e6msxBmF

While there are many types of non-destructive tests, those most prevalent in the foundry industry are Radiography, Liquid Penetrant Testing, and Magnetic Particle Testing. These are most conducive to the general characteristics of the investment casting process. To learn more about how these different types are conducted and their applications, see this month's blog post: https://lnkd.in/e6msxBmF

'Within approximately 10 weeks since the fire, the finished walls were up. More importantly, however, over 90% of the NIC staff was back at work. As President Borthwick recounts “Our Union Associates were the key to our being able to rise from the ashes as quickly as we did. Our people came back to work in conditions that were challenging, to say the least, but they were 100% dedicated and determined to get our business back up and running and keep our customers happy in the face of this disaster. We could not have done it without each and every one of our Associates”. The plant was once again operational, and back to accepting and scheduling their valued customers’ orders for processing.' To read more about how Niagara Investment Castings faced challenges head-on after a devastating fire took place in 2023, click here: https://lnkd.in/gYSm4skk