A trip through FREEZE CAST foundry from design to shipping
Welcome to FREEZE CAST, we open the doors of our company for you to discover the different stages of our process.
How do we manufacture our precision parts? What are these stages like? Let’s take a look at the different sequential phases of this very special process.
Part design: 3D design
With the receipt of the client’s order, the internal process for the manufacture of the castings begins.
Let’s start from the beginning: the part’s design.
3D technology is fully integrated into our processes from the initial product design to final product dimensions.
Our reverse engineering services aim to achieve top-quality products within a competitive timeframe.
This part of the process is a critical stage in our manufacturing method.
We have our own pattern shop, equipped with the latest manufacturing technologies, where we create the highest quality patterns from our customers’ 3D designs.
This is the ideal process for prototypes, short series and/or individual units.
There are several types of materials you can choose to produce a pattern. At FREEZE CAST, we use different materials such as wood, resin or aluminium. All of them finished with their excellent precision and surface quality.
The mould is derived from the initial pattern. It can be made of different materials. At FREEZE CAST we use ceramic moulds. Why ceramics? Check out this entry and discover all the benefits.
The main objective of the mould is to reproduce multiple uniform copies of the final product.
Steps to follow in this process:
- Mould heat treatment
- Mould assembly
A melting process involves the preparation of the molten metal for casting. The molten metal is transferred to the pouring area where the moulds are filled.
In this stage of the process, the melting temperature is higher than 1600ºC (2900F) and it is at this time when we get the Stainless Steel into the mould.
The alloy flows into the mould into each of its cavities. The ceramic mould allows the metal to flow easily through thin, detailed sections. It also creates a casting with improved dimensional accuracy, as the mould and casting will cool and shrink together.
We get the cast material to take the exact shape we have designed to create our customers’ impellers, diffusers or other parts.
Melting, mixing, and pouring metals at these high temperatures is a complex job that requires specialized equipment and careful work.
Workers guide the flow of metal from the furnace to mould behind heat shields, guarding against the dangers of the temperature and materials.
Shake out: Removing of the mould
The process for removing a casting from a mould begins with determining the right time and temperature to do the shakeout.
After the Stainless Steel has been poured, it must cool down to ambient temperature, before unmolding takes place.
Once the casting solidifies, the ceramic moulds break down, and the casting can be removed.
Cutting/ Cut off
Now the parts are prepared for the cutting and blast cleaning process, to remove the feeders and the risers of the part.
The cast parts are subjected to special heat treatments, defined by the material standard specifications of the pieces, in order to achieve the mechanical characteristics of strength, hardness and toughness.
Feetling and dressing
At this stage, we take care of finishing, perfecting and cleaning your pieces by careful grinding, to ensure the castings comply with the requested quality.
We are approaching the end, the time to guarantee the highest quality of the product.
FREEZE CAST’s custom machining services provide exceptional quality and service, no matter how complicated or difficult the part.
Due to the common hazards of corrosion, fatigue and excessive wear; Machining techniques, materials and overall product quality must meet, exceed and meet hydraulic industry standards and specifications.
Our investment in the latest machining tools and equipment enables us to provide the highest quality hydraulic components.
We guarantee part integrity through comprehensive quality control and non-destructive examination (NDE). We also offer balancing and coating, ensuring parts are ready for assembly upon delivery.
All casting processes are subject to specific control procedures:dimensional and visual control, , dye penetrant testing, control by magnetic particles testing, , radiography testing…), ensuring the perfect quality of the final piece
Part quality documentation
The quality of FREEZE CAST is internationally recognised, it is a fundamental pillar of our company. Here you can see our quality policy in more detail.
Your business needs the most precise and accurate parts, FREEZE CAST provides you with these pieces together with the corresponding product documentation.
Sectors such as the Nuclear requires a great deal of control over the documentation of the parts. Regardless of the industry you are in, we provide you with all the necessary information.
Packing and Shipping
Once an order is completed and all the parts have successfully passed the quality control standards, the next stage is the packaging of the products and their shipment.
All the products are carefully packaged to prevent any possible damage and deterioration during the shipping process across the world.