Cost Reduction Examples
Continuous Cast In Deicer Application - The net shaping of components using continuous casting has helped customers avoid expensive machining and milling cost, even for smaller parts.
Food Processing Grinder - Very large 280# investment castings replaced fabrications, reduced labor cost, and provided product consistency for a food processing customer.
Meat Grinding Tube - A meat grinding customer replaced forgings with centrifugals because the multi-directional grain structure of the centrifugal prevented cracking that the unidirectional grain structure of forgings experienced under high stress.
Net Shape Compressor Case - MetalTek's unique Net Shaping reduced machining cost of flight turbine compressor cases by up to 80%.
Net Shape Examples - O.D. features are directly cast to reduce subsequent machining and processing cost. Customers have discovered that the small one-time tooling costs have made net shaping practical even for low volume applications.
Shaft Sleeves - Early alloy development and homogeneous grain structure have established MetalTek as the world's leading producer of naval shaft sleeves.
Sigma Blades - By managing sources of part distortion in the manufacturing process and developing a special alloy, MetalTek was able to provide a mixer manufacturer with large components that would fit into an especially tight tolerance envelope.
Special Machining And Tooling - The ability to avoid a weld in critical hot area was only accomplished by devising a way to machine an 8" deep groove in a 12" part.
Spiral Cast Pipe ID - ID shaping of centrifugals has helped the chemical processing industry improve efficiency by up to 4x by keeping in-process fluid materials moving.
Valve Cages - A hybrid sand and centrifugal casting process eliminated latent defects and machine scrap by 98% in components for a large valve customer.
Vortex Meter Bodies - Versatile tooling and precise manufacturing controls have reduced inventory cost and improved quality of investment castings for meter body customers.
Winch Drum Assembly - When a defense customer changed to non-asbestos linings for a brake application, MetalTek developed a Metal Matrix Composite (MMC) material that reduced operating cost by 90%.
Contact us if you want more details about any of these solutions.
