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JC Casting Lost Wax Investment Casting can provide demanding superalloy casting. Our investment castings are used in the petrochemical industry. High temperature petrochemical casting applications Petrochemical plants require quality and safety under conditions of high temperature and pressure. JC Casting's extensive alloy selection includes dozens of heat resistant grades. They provide exceptional performance for piping and fabricated assemblies operating at extreme pressures from 1,500 to 2,200°F (815 to 1,204°C) for 10 years or more. We can customize special alloy castings according to customers' alloy grades and application requirements.

The oil gas industry is one of the biggest sectors in the world. They can be split into upstream (exploration), midstream (transportation, storage and processing) and downstream (filtering and refining) areas. This market also requires a massive amount of precision castings. Investment castings form the technically-advanced parts required for such a demanding industry.

Military and Defence is one of the most significant sectors for investment casting. Being the oldest and the most advanced of the metallurgical arts, it has proved as the best option for making several vital components specific to the military industry. Military & defense castings include components for weapons, vehicles, planes, and firearms. Defense equipment and tools are used in tough conditions. So we also make castings that are capable of withstanding extreme conditions. Our castings can withstand tough environments. The castings are meant to stay strong for a long period of time. The castings are highly reliable and strong. As they are used with high-specification materials and cutting-edge manufacturing techniques.

Nickel alloy casting is an industrial process used to manufacture components from various alloys. This method of production has been around for many years but is becoming more popular due to its cost-effectiveness, speed and accuracy. In this blog post, we will discuss nickel alloy casting, the types of alloys that can be used in the process, and the benefits of using it. What are Nickel Alloy Castings? Nickel alloy casting is a lost wax casting process in which molten metal, usually a nickel alloy, is poured into molds made of wax or other material that becomes liquid when heated. The molten metal takes on the shape of the mold as it cools, filling any cavities or holes in the mold. The result is an exact replica of anything created from the mold. Types of alloys that can be used Nickel alloy casting can be used with a variety of alloys depending on the desired result. Some common examples include stainless steel, bronze, brass, aluminum, and iron alloys. Different metals have different properties that make them better suited for certain applications, such as strength or corrosion resistance. Choosing the right alloy for your application based on your requirements is crucial. Benefits of Using Nickel Alloy Casting Casting with nickel alloys offers several advantages over other manufacturing processes such as machining or injection molding. This type of production allows for greater precision, as each part can be produced identically, since each part is exactly like its molded counterpart every time. It's also less expensive than other processes and can be done relatively quickly, making it ideal for mass production or a quick turnaround if needed. Also, because no cutting tools are involved in creating a part with this method, it produces parts with less waste than machining or tooling methods that require removing excess material to create shapes and features.

This method is ideal for making small complex geometries with complex features with one mold. Investment casting is used in many ways. Because you can combine multiple wax patterns to create a unique mold, you can configure parts that you cannot machine or tool make, making them a valuable alternative to weldments. Dimensional accuracy and finish are other benefits of this casting method. The casters form the ceramic shell around a uniform pattern, leaving no parting lines because there is only one mold instead of two for casting. The result is a smooth finish averaging around 125 micro-finish, but a finer finish can be achieved with post-process smoothing if necessary. Other advantages of investment casting include: Reusable Material: Design engineers can reuse melted wax for another pattern. They can also reuse the molds due to their strength. Tight Tolerances: Investment casting has a tolerance of 0.003 inches, which is tighter than most casting processes, such as die casting. Design Capabilities: With investment casting, design engineers can add identifying markings such as numbers, logos, and product IDs to castings.

High pressure die casting is a process in which molten metal is fed into a mold and solidifies to obtain the desired part. Molten metal is forced into the mold cavity under high pressure (usually hydraulic pressure) and held in place by a powerful press. Once solidification is complete, the casting is removed by opening the mold. After the final product is ejected, the mold is locked again for the next production cycle. High pressure die casting tools consist of two steel blocks that form the ends of the mold cavity that forms the desired object.

Stainless steel casting, also known as stainless steel investment casting, refers to the formation of ceramics around a wax pattern to form a shell for casting stainless steel. Once the wax patterns are created, they are melted into a gating system, dipped in mud and sand to form a layered shell, and then replaced with molten stainless steel. How are stainless steel castings made? Stainless steel casting involves creating an original wax model, building the image with plaster and successive layers until there is a solid shell around the model. After the wax has melted, the molten stainless steel is poured into the mold, creating a perfect replica of the original wax pattern. Stainless steel castings provide economical undercuts, high resolution, fine detail, and a smooth surface finish compared to machined separations. In most cases, stainless steel castings are the only way to manufacture parts economically. Advantages of stainless steel castings Sizes: 0.1" to 24" Weight: a few grams to over 50 pounds Surface: very smooth tight tolerances Reliable process control and repeatability Versatility in Design and Casting efficient production affordable tools Material Variety

Investment casting uses a wide range of ferrous and non-ferrous alloys, each with different advantages such as cost, strength, temperature or corrosion resistance. We work with over 75 different fume casting alloys to provide you with the perfect solution for your precision investment casting requirements. The following are several common investment casting materials: stainless steel casting Stainless steel castings are used in aerospace and defense and other industries that require non-corrosive components that provide the tensile strength required for demanding applications. Stainless steel is also used in investment casting in the food industry and medical, mining and plumbing applications. Our cast stainless steel materials include 17-4 PH, 15-5 PH, and 300 and 400 series stainless steels. carbon steel castings Investment casting using carbon steel produces wear-resistant precision parts. Carbon steel is cost effective and easy to machine. It can also be heat treated to increase its strength and ductility, and is available in a variety of alloys. Carbon steel casting materials are used in a range of industries including mining, military and industrial applications. tool steel casting Tool Steel Casting The material is a carbon alloy steel that resists wear and retains its shape at high temperatures. It is often heat-treated to increase its hardness and is often used to make tools and equipment designed to cut, press, or shape other materials. F Nickel-based alloys are used in investment cast parts that will be used in demanding applications in the oil and gas, medical, nuclear, and aerospace and defense industries. This material is versatile, corrosion resistant and able to withstand high temperatures. Nickel alloy casting materials include stainless steel, nickel-chromium alloy, nickel-copper alloy, etc. cobalt based alloy Cobalt-based alloys are investment casting materials alloyed with nickel, chromium, and tungsten. They have excellent hot corrosion and thermal fatigue resistance and are ideal for high temperature applications. Cobalt-based alloy casting materials are commonly used in jet engines in the aerospace and defense industry, as well as in nuclear energy and electric power applications. aluminum alloy Aluminum alloy casting materials are used in many aerospace applications because they are lightweight and corrosion resistant. These alloys typically contain elements such as copper, magnesium, manganese, silicon, tin or zinc, each with different casting properties. We use 300 series aluminum in many investment casting applications. The advantage of 300 series aluminum is that it has high tensile strength and ductility for pressure applications.

X-Ray testing is one of the best non-destructive inspection methods for detecting internal defects of castings. In this method, the tested product is exposed under x-ray radiation. Parts of the radiation are absorbed by the product, and the remaining portion of the radiation exposes the radiographic film. Dense material withstands the radiation penetration, so the film is exposed to a lesser degree in those areas, giving the film a lighter appearance. Less dense materials allow more penetration and correlates to darker areas on the film. Any hole, crack or inclusion that is less dense than the casting alloy is revealed as a dark area. X-Ray testing is able to find internal defects of investment casting product including gas porosity and gas holes, shrinkage which appears as dendrite/filamentary/ jagged, cracks and so on. Content source:https://www.jccasting.com/blog/x-ray-testing-in-investment-casting/

Leak testing is the process of checking a system for leaks (a defect). Leak testing can be achieved using various leak detection methods and is employed to test for defects in products and to ensure the proper function and maintenance of industrial systems and pipelines. The choice of the detection method depends on which method is most appropriate for the system at hand. There are several points on performing leak test: 1. Leak test shall be conducted after passing the hydraulic test. The leak test can be carried out simultaneously with the air pressure test for the pressure vessel required by the design. The test pressure shall be the pressure of the air pressure test. 2. The gas used in the leak test should be dry, clean air, nitrogen or other inert gas. 3. When conducting leak test, safety accessories should be fully installed. 4. During the test, the pressure shall rise slowly, after reaching the specified test pressure, the pressure shall be maintained for no less than 30 minutes, and then the pressure shall be reduced to the design pressure. All welds and joints shall be coated with soapy water for inspection, and no leakage shall be considered as qualified. In case of leakage, hydraulic test and leak test shall be conducted again after repair. Content source:https://www.jccasting.com/blog/leak-testing-in-investment-casting/

Ultrasonic nondestructive testing, also known as ultrasonic NDT or simply UT, is a method of characterizing the thickness or internal structure of a test piece through the use of high frequency sound waves. The frequencies, or pitch, used for ultrasonic testing are many times higher than the limit of human hearing, most commonly in the range from 500 KHz to 20 MHz. The time interval between the transmitted ray and reflected ray is recorded by a cathode ray oscilloscope. Any crack or void in the casting results in reflection or some of the sound from the crack which appears as a pip between the two pips representing the thickness of the casting. The depth of the crack from the surface of the casting can be easily calculated from the distance between these pips. Ultrasonic inspection is generally carried out after heat treatment, because of the high requirements for surface roughness. After heat treatment, the surface of steel casting products have oxide skin, which has to be cleaned by surface treatment process. In other word, if ultrasonic testing is before heat treatment testing, there are two repeated and wasteful surface treatment processes during manufacturing. Moreover, heat treatment can also lead to the defects of casting parts, such as cracks. For more information on Ultrasonic nondestructive testing, click here.