Save time, money, and receive a better product by converting to a casting process
The drive to reduce costs is a relentless effort for nearly all manufacturers. In the case of purchased components, the determination of comparative cost is relatively simple. Comparing the cost of alternative methods of manufacturing for a component or set of components is more difficult. But the replacement of multi-piece weldments or highly-machined hogouts by single piece castings has been proven time and again to be one of the most effective ways to reduce real product cost.
For example, a major U.S. defense contractor enlisted MetalTek’s assistance for a technical and manufacturing review of key components to target ones most likely to contribute to their cost reduction goals. A number met the customer’s cost and quality criteria and have subsequently been tooled and converted to production castings, with an average all-in cost reduction of more than 15%.
Another example was described by the customer as a “fabrication nightmare”. In this example, grid components need to mate together in a pulp dewatering system. The grids operate in a pulp and paper environment that demands the corrosion-resistant qualities of nickel-based alloys like those in the Monel® family. These alloys provide superior corrosion resistance, but with their strength comes hardness that makes further processing and machining more difficult than many other alloys. The customer relies on MetalTek’s ability to provide components very close to the required net shape in these demanding alloy grades. By casting in the grates and fins, the customer avoids fabrication welds and a tightly controlled manufacturing process solves a mating part challenge as well.
Contact MetalTek International today to talk about converting challenging applications to a single piece casting. The only thing you have to lose is cost.