Rapid Manufacture of
High-Integrity, Safety-Critical
Cast Components for the
Petrochemical Industry
World-Leading Petrochemical Casting Specialists
Combining industry-leading advanced foundry technology and extensive experience to innovate casting manufacture and deliver high-integrity, safety critical sand castings for the Petrochemical industry worldwide.
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32 Core MAGMA Simulation
3D Mould Pack Design
Tool-less 3D Sand Printing
Prototype & Series Foundry
5-Axis CNC Machining
Metallurgy, NDT, CMM
The Complete Design & Manufacturing Hub for Creating Petrochemical Industry Cast Components
At Finecast we develop, engineer and manufacture cast components for the petrochemical industry, including pump housings, impellers, valve bodies, bonnets, actuators, flanges, fittings, connectors, structural elements and complex geometric shapes.
Cast components play a critical role in petrochemical engineering, with our clients requiring high-integrity, safety-critical sand castings to ensure efficient, reliable and safe operation of petrochemical processes.
Our experienced team of engineers and metallurgists have the knowledge and expertise to design and engineer high-quality castings to meet the required mechanical properties, ensuring they can endure harsh environments, combat corrosion, and retain structural integrity.
We specialise in casting a range of ferrous and non-ferrous metals, including austenitic, ferritic and duplex stainless steels, heat and wear resistant steel and iron grades, aluminium alloys and nickel and copper-based alloys.
Finecast provides a full-service solution for petrochemical industry cast components from our state-of-the-art facility, based in Littlehamption, West Sussex. Our technologically advanced manufacturing processes include, virtual casting simulation, 3D mould pack design, 3D sand printing, pattern tooling, prototype and production volume foundry, heat-treatment, metallurgical testing, non-destructive testing (CT Scan & Radiography), 3D optical scanning, 5-axis CNC machining and CMM dimensional validation.
Our advanced manufacturing facility, technical processes and engineering experience enables us to deliver each and every casting exactly to our customers specification, meet the tightest deadlines and deliver castings of the very highest quality standards.
Precision Sand Casting for the Petrochemical Industry
Our specialist prototype facility allows us to rapidly manufacture high-quality, technically challenging cast components as one-off’s or in low volume. This allows for practical verification of design, structural integrity, and performance before transitioning to large-scale production.
To achieve this, we leverage our on-site technologically advanced processes including Magmasoft® 32 core virtual simulation, metallurgical testing, 3D sand printing, prototype/low volume foundry, non-destructive testing (including CT scanning and radiography), CNC machining and CMM dimensional validation, all supported by our extensive petrochemical engineering casting knowledge and expertise.
Our rapid prototyping casting service can deliver ‘make-like-production’ petrochemical cast components in just weeks, helping our clients significantly reduce their product development cycle times.
> Low/Medium Volume Series Sand Casting Foundry
Our sand foundry provides us with the flexibility to accommodate initial production builds up to scheduled production of up to 5000 units. We cater to the low/medium volume production of petrochemical castings in a range of materials including steel, aluminium, iron, nickel, copper and chrome based alloys.
Our continued investment in advanced robotic foundry equipment, such as automated mixers and high-speed mould fill and close stations, ensures efficient, consistent processing for components up to 3 msq and minimum wall-thickness of 2.5 mm.
Finecast’s foundry engineers employ our HPLT/durville process technologies to achieve low turbulence pouring, ensuring defect-free component quality.
Our foundry is also fitted with an advanced thermal sand reclamation system, which allows us to recycle up to 95% of the sand we use. This not only boosts the efficiency of our sand casting manufacturing process but also greatly reduces our carbon footprint. Additionally, this provides us with the opportunity to enhance our sand quality during the thermal reclamation process, leading to exceptionally high-quality castings with superfine surface finishes.
Our on-site thermal processing facility enables us to treat large castings to enhance their physical and mechanical properties. Our largest solution furnace has a volume of 11.56m³ (2.15m x 2.15m x 2.5m). We use a variety of water and polymer quench methods to manage distortions and residual stresses in all components in line with client specifications.
Testing & Validation for Petrochemical Industry Sand Castings
> Chemical, Composition & Mechanical Analysis
Our in-house laboratory is equipped with specialised laser spectrographic tools, allowing full traceability of process parameters for validating the chemical, composition, and mechanical analysis of various types of casting materials and sand media.
Our MA-accredited metallurgists are on hand to conduct a meticulous review of the melt samples throughout the production phase to ensure the chemical composition aligns perfectly with the client’s specific engineering requirements. Our comprehensive spectrographic review procedures enable us to consistently deliver flawless, high-integrity petrochemical castings.
Our wealth of expertise in this field enables us to formulate unique alloy compositions that enhance the durability, ductility and corrosion resistance of safety critical petrochemical cast components used in transferring aggressive and hazardous liquids and gasses.
Our sophisticated verification procedure, utilising optical scanners (GOM/Creaform), ensures dimensional precision and stability by generating a 3D model that is overlaid on the original architectural part CAD model. This process enables strategic alignment between casting and machining datums, guaranteeing the delivery of precisely machined castings that meet the customer’s specifications.
Ensuring high-integrity and defect-free petrochemical cast components is critical. We employ the powerful GE Seifert X|Cube 320KV CT Scanning System, providing the best non-destructive testing (NDT) services in the UK, effectively identifying micro porosity, minimal incipient cracks and surface flaws for every casting we manufacture.
Our castings undergo thorough testing to ensure their integrity using air decay or hydrostatic pressure testing techniques. With this approach, we can authenticate cast components, replicating various leak rates and test pressures.
CNC Machining for Petrochemical Industry Sand Castings
Our advanced machining department provides a comprehensive, all-in-one service. With an array of high-grade 5-axis Mazak CNC machining units and precision turning tools, along with our experienced team of engineering specialists, we are able to deliver consistent, close tolerance, high precision components in a variety of material grades for the petrochemical industry.
Dimensional Validation for Petrochemical Industry Sand Castings
Our state-of-the-art in-house metrology laboratory is equipped with hi-tech inspection and validation tools, including three Coordinate Measuring Machines (CMMs) and sophisticated programming software with programmable probe stations, enabling us to measure components of up to 2 metres.
We also utilise our sector-leading ‘Hobson Taylor Talysurf’ measurement tools to quickly and accurately verify surface finishes, contours, and angle measurements.
This cutting-edge technology, combined with our highly skilled inspection team, allows us to deliver petrochemical castings that fulfil our customer’s requirements, including CPK Indices, SPC analysis, comprehensive ISIR and FAIR reports.
Working in Partnership with World Leading Companies
