Testing & Validation for Defence Industry Sand Castings

> Chemical, Composition & Mechanical Analysis

At Finecast, we pride ourselves on our sophisticated laser spectrographic technology which allows us to track and validate the chemical, composition and mechanical properties of sand media and casting materials. Our knowledgeable team of MA-qualified metallurgists perform rigorous spectrographic analysis on all molten samples throughout the production process in order to guarantee that they meet our defence customers’ exact engineering specifications.

Our comprehensive spectrographic analysis enables us to produce consistently high-quality, defect-free millitary and defence castings every single time. We are proud of our decades-long experience in this field, which allows us to develop special alloy compositions for lightweighting, ductility, durability and thin-walled parts.

> Heat Treatment

Our onsite heat treatment facility offers a powerful solution to improve the mechanical and physical properties of large castings. Our largest solution furnace has a volume of 11.56m³ (2.15m x 2.15m x 2.5m), which enables us to treat components of all sizes with precision and accuracy. We use a range of water and polymer quench techniques to control distortion and residual stresses in components, making sure that the customer’s exact specifications are met. Cast components can be processed to international or bespoke conditions and conform to Aerospace standards by recording temperature and cycle times to give full traceability.

> 3D Geometric Optical Measurement

Our rigorous inspection and validation process using state-of-the-art optical scanners (GOM/Creaform) ensures that each part is produced to exact dimensional accuracy and stability. Two 3D models are created: one of the casting and one of the parent CAD model. The two models are precisely aligned, allowing for a perfect, precise fit between the two. This verification process guarantees that all parts are delivered to our customers precisely according to specific design and engineering requirements.

> Non-Destructive Testing – 2D Radio Tomography & 3D Computer Tomography

At Finecast, we take pride in our commitment to producing components with the utmost integrity and quality. To ensure that each cast component is free from defects, we utilise our advanced GE Seifert X|Cube 320KV CT & RT Scanning System. This cutting-edge technology allows us to detect even the most minute imperfections or incipient cracks, ensuring that all of our components are defect-free.

> Pressure & Leak Testing

The integrity of our defence castings are checked and verified by using air decay or hydrostatic pressure testing. We are able to verify core complex components with intricate oil galleries such as engine blocks and cylinder heads by repeating various leak rates and test pressures.

Dimensional Validation for Defence Industry Sand Castings

> Machined Component Dimensional Validation

Our in-house metrology laboratory is a highly advanced facility that allows us to inspect and validate each and every casting project with precision. Our validation technology is comprised of three Coordinate Measuring Machines (CMMs) outfitted with fully programmable probe stations, which can measure machined defence cast components up to two meters in length. We are also equipped with a Hobson Taylor Talysurf for quick and accurate surface finish, contour, and angle measurements.

Our investments in the latest inspection technologies, combined with our team’s experience and knowledge, allows us to perform detailed validations that exceed customer requirements and expectations. Such validations include CPK indices analysis, Statistical Process Control (SPC) reports, full Initial Sample Inspection Reports (ISIRs) and First Article Inspection Reports (FAIR). Our metrology laboratory is a key factor in the success of each casting project.