Quality at Every Step
Casting process control begins and ends with our process sheet, also known as the work construction. The process sheet assigns every product a part number, along with a list of operations that each part will undergo. All ETPL departments, from tool making to packaging, can refer to the process sheet to verify what actions were performed at previous stations and what is in queue. This internal checks and balances system produces the most consistent results with the highest levels of part-specific control.
3D modeling, either customer-submitted or in-house designed, is included with the process sheet to guarantee tooling accuracy. With over 35 years experience in tool making, ETPL engineers are experts in gating tooling models with pinpoint precision. Samples are run to verify tooling accuracy. Visit our casting tooling page for additional information.
Our wax room is equipped with temperature and humidity controls to manage the consistency of our wax patterns. To avoid wax dimensional changes, we purchase wax exactly to our specifications. We adhere to all temperature tolerances outlined in the process sheet to eliminate wax expansion and contraction.
Once again, temperature and humidity are the focal point of our dip room process control. We use proprietary formulas for our slurries which are designed for maximum consistency. Each part has different dipping procedures, which are clearly outlined in the process sheet.
Computerized temperature controls are built into our dewaxing equipment. Our dewaxing equipment quickly ramps up to the temperature specified in the process sheet, holds that temp for a period of time, then ramps down.
The process sheet outlines part-specific pouring and shell temperatures, as well as solidification control techniques. Chemical analysis is performed at this station to verify the chemistry of the metal.
Here we perform blasting, grinding, and runner system removal from parts. Once again, the process sheet dictates information on part-specific blast types and gate grinding.
We can meet all heat treatment requirements, including MIL-H-6875. Please refer to our heat treatment page for more information on our heat treatment services.Non-destructive testing through a combination of in-house resources and outside vendors, we can meet any NDT specification. Our casting designers can also assist with developing part-specific NDT techniques.
Precisions Casting of Tennessee’s metal chemical analysis services offer accurate analysis of everyday casting production, as well as value-added customer service and quality assurance. Our two optical emission spectrometers can measure the elemental composition of any low alloy, high alloy, stainless steel, tool steel, or precipitation hardening steel.
ETPL can also spectro analyze nickel based, cobalt based, bronze, and cast iron materials such as ductile iron. Whether metal chemical analysis is required in-house or at customer request, ETPL adheres to a host of NIST and BS reference standards to ensure each spectro analysis is accurate beyond industry standards. Contact our metallurgical laboratory for more information on spectro analysis and other metal chemical analysis services.
INSPECTION AND TESTING
Meeting customer specifications is our number one priority. Our series of non-destructive testing and chemical spectral analysis procedures ensure that every casting meets your intended dimensional accuracies, design tolerances, and structural integrity requirements. Fluorescent Penetrate Inspection – By applying a fluorescent dye to the finished casting, ETPL can detect surface cracks, leaks, and defects that could potentially compromise structural integrity.RADIOGRAPHIC INSPECTION (X-RAY)
This inspection method bombards the casting with short wavelength electromagnetic radiation to expose surface and subsurface imperfections.
MAGNETIC PARTICLE INSPECTION
This non-destructive testing method consists of applying a magnetic field to the part undergoing testing.
MECHANICAL PROPERTY TESTING
ETPL performs tensile, hardness, and toughness tests to measure fractures, deformities, or fatigue of any alloy type. Mechanical property testing can accurately predict the amount of stress a casting can withstand before structural failure.
INTERNAL BORESCOPE INSPECTION
Borescopes can visually inspect internal geometry that would be impossible to detect with other methods. This inspection is useful for identifying burrs, surface defects, or voids that are not immediately apparent.
Measures the elemental composition of any low alloy, high alloy, stainless steel, tool steel, or precipitation hardening steel.
PHYSICAL PROPERTY TESTING
This test is useful for determining how an alloy will react under controlled environmental variables such as temperature and humidity.