New Yorker Electronics is offering advanced new metal casting capabilities from AMFAS International. These processes include die casting, investment casting and sand casting in stainless steel, carbon steel, aluminum, copper/brass and super alloys (Inconel).
Die casting, a process similar to injection molding, uses a die or mold 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 mold 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 produces parts to 50 lb with aluminum alloys, zinc and magnesium. Equipment includes 280 ton to 2,000 ton high pressure die casting machines, robotic material handling and centralized furnace and dumping furnaces.
Although labor 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 can advise on the best casting option given the material, part geometry, volume and other considerations. Part sizes range from 1 oz to 150 lb and materials used include stainless steel, carbon steel alloys, aluminum alloys, super alloys (Inconel), copper and brass alloys and iron.
In the case of sandcasting, sand acts as the mold 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 mold are joined together and the molten metal is poured into the sand mold. Within a few minutes, the metal cools and the sand mold is removed using vibration and mechanical means. With AMFAS International, the sand is then pulverized, 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 and brass alloys and iron for sand casting.