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.

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

Computer Tomography | Digital Radiograph: GE Seifert X|Cube 320KV System.

The General Electric Seifert x|cube 320 KV scanning system is used at Finecast as a validation tool to verify the integrity of our castings. The system generates a 3D model super imposed against client data for dimensional assurance.

The Seifert x|cube Computer Tomography system uses scatter cone beam which allows the region of interest to sit central in the field of view for the cone beam.

A single 360 degree rotation then captures the volumetric data set in the region of interest. The scanning software then collects and reconstructs the data to produce a 3D model which can be manipulated for:

  • Defect analysis: Micro-Porosity, Sand Inclusion, Dimensional Stability, Sub-surface cracks and Shrinkage Porosity
  • Wall thickness Measurement
  • Internal Core Location
  • Reverse Engineering

This technology allows for a fast and efficient method of identifying incipient cracks, sub-surface defect and dimensional verification in a non-destructive process. As a consequence we have a high level of confidence in the assessment of our quality which results in a continued process of improvement.

Pressure | Leak Testing

The integrity of our castings are also checked using air decay or hydrostatic pressure testing as defined in the customers technical agreement.

Our engineering team develop bespoke testing fixtures to the pre-defined inspection strategy. The experience of our team verifying core complex components with intricate oil galleries such as Engine Blocks and Cylinder Heads repeatably to various leak rates and test pressures.

The challenge for Finecast is providing our customers within Automotive, Defence, Rail and Motorsport quality systems and tools tailored to meet the clients quality objectives. As a consequence major improvements in project management systems to deliver excellence in our castings and operating standards.