Cast Product Validation
Repeatable and consistent defect free castings is achieved by comprehensive technical process control and in house investment into the most advanced CT scanning, digital radiograph and CMM laser technology offering cast integrity and dimensional assurance.
In House Laboratory: Chemical, Composition & Mechanical Analysis.
Finecast Foundry ensures full traceability of process parameters to validate the Composition, Mechanical and Chemical analysis of the various sand media and cast material using our laser spectrographic units.
The spectrographic analysis of the melt sample is carried out throughout production to ensure the chemical composition of the cast material conforms to the customer’s engineering specification.
The results collected create the foundation for the physical, mechanical, and chemical analysis of your product. To ensure your specification is met within its entirety to process to support your design parameters.
- Multiple Spectrometers
- Nitrogen Analysis for Ferrous and Non-Ferrous Alloys
- Microscope with image analyser software
- Tensile Testing
- Ultrasonic Testing
- Dye Penetrant Inspection
- Magnetic Particle Inspection
Geometric Optical Measurement (GOM/Creaform Technology)
Finecast uses a blue light optical scanner to ensure dimensional stability by mapping the external profile of the casting to create a 3D CAD model.
As the geometric optical scanner only captures the external geometry of the casting. To capture the internal profile of the casting, we utilise our G.E 320 K|V C.T scanner.
The images captured to create a 3D representation of the cast part is then superimposed against the parent data to ensure dimensional accuracy and stability to be signed off as feasible for batch manufacture.
Our machinists also use the 3D model and report created then converts into a solid model for compatibility with CAD/CAM. The result generated from this activity aid the machining team in strategically aligning the casting to set X, Y & Z pick-up coordinates.
- Optical Scanners (GOM / Creaform) – Reverse Engineering Capabilities
- Tooling Configuration to casting geometry irrespective of size
- Variance report to Customer data
- Fast and efficient data capturing hardware.
- Strategic alignment of castings in line with machining datums
In House Computer Tomography System
Inhouse Investment into General Electric’s latest Seifert x|cube 32CT scanner technology establishes us as having the most advanced computer tomography with the foundry industry guaranteeing complete casting integrity and dimensional assurance of all components.
CT qualification is central to our NPI validation process of new cast designs and all critical components are 100% scanned to guarantee casting integrity. Unlike other digital radiography, this advanced technology is the first industrial scanner on the market to employ scatter correct fast cone beam scanning to an accuracy of 0.1mm so even micro porosities can be identified.
Large cast components including those with steel wall sections up to 90mm can be rapidly scanned within minutes with an exacting 3D high definition model generated to identify the size, volumes and density of cast inclusion and cavities.Internal geometric and wall thickness measurement can also be qualified without the need to section the casting unlike other conventional CMM technologies.
The commissioning of this technology on the foundry floor guarantees total cast integrity product and rapid resolution of defects. Critical information obtained from this technology also supports our development and knowledge going forward. All scan results are analysed against our MAGMA casting simulations allowing for us to finite calibrate the software for future simulations. These results provide also provide a valuable insight to customers and can also be used as part of FMEA analysis.
Pressure Testing
Casting integrity is also checked using either our air decay or hydrostatically testing in accordance to your technical specifications.
Our engineering team have expertise designing bespoke test fixtures and testing complex multi internal core galleries components such as engine blocks and cylinder heads to repeatable and tight specifications. All tests are performed to robust process control procedures with leak and test pressure reported for each gallery.
