ADVANTAGES OF OUR INVESTMENT CASTING TECHNIQUE; High surface finishes quality (Ra 3.2-6.4) Close linear tolerances (DIN VDG P690) Near net shape Cevik Technical Metallurgy was founded in 2011 in Tuzla-Istanbul, Turkey. With 25 years of experience and 1,500 square metres production area -fully equipped with the latest investment casting technology and infrastructure, we are already recognised as one of the main players of Investment Casting Industry in Turkey. Our Ceramic Mould Investment Casting Method (Low Wax Investment Casting) gives completely different advantages comparing to traditional Casting Methods; close linear tolerances, high surface quality, near net shape for complex parts, wide range of alloy selection for better performance İOur mission is not only limited with casting but to be a solution partner for your design and for the selection of the most efficient production method and alloy type. Flexibility in Weight: end products from 1gr to 40 kgs Flexibility in Alloy Selection Ferrous alloys: all kinds of steels Non-ferrous alloys: copper based, aluminium based, nickel based, cobalt based Flexibility in Design: Almost any kind of complex geometry which are difficult in traditional casting methods Thicknesses down to 0,5mm One part casting, no split lines Freedom in internal geometries Flexibity in Quantities Cost effective method even for low quantities Consistency and Standardisation in High Quality CONSISTENCY FOR HIGH QUALITY IS OUR ROAD MAP We believe that Consistent Quality is never an accident; it is always the result of high intention, sincere efforts, intelligent direction and skillfulexecution. In this sense, we steer our quality control to raw materials and production method parameters rather than the quality control of end product itself. Additionaly, we can check end product by means of different destructive and non-destructive testing techniques. Low Tool Cost Best Material Characteristics Microstructure with fine grains. High material charesteristics due to low porosity, inclusions and segregations Weight reduction by means of design and best material characteristics.
INVESTMENT CASTINGS COST ADVANTAGES Provides near net shape lowers material usage Reduces material costs Reduces expensive machining operations Eliminates expensive production and welding costs Low initial mold and tooling costs Economic order quantities: both for prototype quantities and mass production quantities MARKETS WE SERVE Aerospace Industry Automotive and Railway Industry Energy, Power Generation Agriculture Defence Industry Medical, Orthopedics Textile Industrial Pumps and Valves Machine Tool Industry Food and Dairy Processing Others ADVANTAGES OF OUR INVESTMENT CASTING COMPARING TO OTHER TRADITIONAL PRODUCTION METHODS SAND CASTING Finer surface quality Closer dimensional tolerances Lower or none draft angles No split lines Superior material microstructure and much less porosity, inclusions and segregations Lesser need for machining MACHINING Lesser need for Machining by means of Near net shapes No material loss Casting of different material types, shapes and geometries which are not possible to produce by Machining High production capacities (rates) Low cost FORGING Finer surface quality No split lines Homogenous internal stress Low cost due to lesser Machining Products with holes, spaces, pockets and internal geometries which are not possible to produce by Forging Lesser cost of molds WELDING Cost reduction, by changing the design from many welded parts to one part investment casting Higher mechanical characteristics by the elimination of welding defects and ITAB areas Finer surface quality Design freedom; not limited to fixed elements i.e.rods or metallic sheets Possibility to create logo, writings and complex figures on the casting BLANKING/BENDING(TWISTING)/DEEP DRAWING More design flexibility Flexibility in production of complexgeometries Low mold production cost and maintenance cost Possibility to create logo, writings and complex figures on the casting Designing different wall thicknesseson the same product Unlimited material / alloy selection POWDER METALLURGY/MIM Finer surface quality and close linear tolerances Producing more complex geometries No shrinkage as in sintering process in powder metallurgy Homogenous microstructure to minimise linear tolerance defects Unlimited dimensions and weights to produce Low mold cost Unlimited material / alloy selection
ALLOYS WE CAN POUR As Cevik Technical Metallurgy, we can pour over hundred alloys for investment casting: ferrous as well as non ferrous alloys. Most common alloys for investment casting are : Austenitic Stainless Steel Low Alloy and Carbon Steels Martensitic Stainless Steel Tool Steels Nickel Base Alloys Cobalt Base Alloys Aluminıum Alloys Copper Alloys (Brass / Bronze)
- DESIGN CRITERIAS LINEAR TOLERANCES General Linear Tolerances British System Up to 2 : +/- 0.020, additional +/- 0.010 for each additional inch Metric System Up to 50mm : +/- 0.50mm, additional +/-0.25 mm foreach additional 25 mm Standard Linear Tolerances British System Up to 1/2 : +/- 0.007 Up to 1 : +/- 0.010 Up to 2 : +/- 0.015 For each additional inch, additional : +/- 0.005 Metric System Up to 15 mm : +/- 0.20 mm Up to 25 mm : +/- 0.25 mm Up to 50 mm : +/- 0.40 mm For each additional 25 mm, additional : +/- 0.13 mm It is advised to use Standard Linear Tolerances for functional part dimensions Special Linear Tolerances Advised Techniques if linear tolerances are required: i) Re-design the product with additional bars, brackets and gussets ii) Adjusting wax injection wax to the nominal dimensions after the prototype iii) Flatness and Straightness iv) Jigging and manual straightening v) Machining vi) Other secondary treatments Premium tolerance practicability should be checked for each diemension of each part. Other Tolerances Straightness-Flatness Depending on the lenght, Parts can be casted straight and flat within 0.10 mm tolerance. For thicker parts this tolerance can be up to 0.25 mm. Roundness Hole profile is within Standard Linear Tolerances. When required, Premium Linear Tolerances can be applied. If possible, it is advisable to apply General Linear Tolerances. Concentricity The gap between the centers of two cylindrical surfaces -which are sharing a common point or an axis as their center-, is not more than the gap between their diameters multiplied by 0.10 mm. If the height of a cylinder is more than two times of its diameter Straightness Tolerance should be added to eccentricity. Angularity As a standard rule, +/- 0.5 degrees or +/- 0.02 ofthe length is a normal tolerance for production. For some cases, Angular Tolerance can go down to +/- 0.25 degrees or go up to +/- 1.0 degrees
Cast Characteristics General Rules Hole Diameter Hole Length Between 1.5mm to 2.5mm: 2 x hole diamater Between 2.5mm to 5.0mm: 3 x hole diamater Between 5.0mm to 10mm : 4 x hole diamater Over 10mm : 6 x hole diamater By using ceramic core, hole length can be increased to 30 x hole diameter. Blind Holes Hole Length = Hole Diameter Counterbores / Grooves Blind grooves can be casted up to 1.5 x width Wall Thicknesses / Corner Radius (Radii) Minimum Wall thikness and Corner Radius depends on the configuration and the dimensions of the part. In some casts, it is possible to have 0.3mm Wall Thicknesses and R 0.3mm Corner Radius. Surface Roughness Standart Surface Roughness in İnvestment casting is125 RMS (Ra3.2-6.0). It is possible to improve Surface Roughness by using secondary methods and treatments. Runners For each section, one or more Runners with a thicker cross-section are used. After solidification, these Runners are removed by Grinding. Internal Radii, Fillets Internal radii and fillets improve the strength andintegrity of the casting and minimise internal stresses. It is advisable to increase Internal Radii Engraving Engraving should be raised letters on a recessed pad, so the top of engraving is below the surface of the part which is easier, more economical and without any defects. Metallurgical and Visual Quality Requirements Design, Material Type, Heat Treatment and Visual details should be discussed and decided between Customer and Cevik Technical Metallurgy. Specific Requirements All other requirements should be discussed and clarified together with our Technical Team before Order and Production
SOME INVESTMENT CASTING SOLUTIONS Design Advantage Application: Machinery Design Problem: High manufacturing costs, difficultweldment, Poor quality Solution: one piece investment cast, quality improvement, 20% cost reduction Performance Advantage Application: Bottling Performance Problem: Short life time, High wear, High costs Solution: New product with cobalt based alloy, Product life time increased, 30% cost reduction Cost Advantage Application: Material Handling Cost Problem: Difficult to machine, Complex shape, Unusual alloy Solution: Investment cast component, 50% savings Here above example is still under design. Our Application Team worked together with our Customer to find an optimum solution using Investment Casting. Advantages of Investment Casting on this Design: Number of total parts were decreased from 33 pcs. to 10pcs. Stainless steel was used instead of carbon steel Dimensions are reduced and total weight was decreased Mechanical properties of load carrying components were improved Consistency on Standart Quality Weldement and Machining Processes were eliminated Much better aeshetics Engineering wise Approximately 65% Cost Reduction