Casting Simulation Software: Reduce Casting Defects TL;DR: Casting simulation software predicts mould filling and solidification before pouring, so defects are fixed on screen, not on the shop floor. Tools like MAGMASOFT and ProCAST cut porosity, shrinkage, and scrap in investment casting. Casting simulation software models how molten metal fills a…
AS9100D Certification Explained: Aerospace QMS Guide TL;DR: AS9100D is the aerospace quality management standard. It builds on ISO 9001 and adds aviation, space, and defence requirements such as risk, configuration control, and first article inspection. It is effectively required to supply aerospace castings. Here is AS9100D certification explained for casting…
Turbine Vane Casting: Nozzle Guide Vanes & Cooling TL;DR: Turbine vane casting produces the stationary aerofoils that direct hot gas in a gas turbine. Cast in nickel or cobalt superalloys, nozzle guide vanes are usually cooled with internal passages to survive the gas temperature. Turbine vane casting makes the vanes…
Gating and Riser Design Casting: A Practical Guide TL;DR: Gating and riser design casting controls how metal fills the mould and feeds shrinkage as it solidifies. Good gating and riser design casting prevents porosity and produces sound investment castings. Gating and riser design casting is the engineering behind every sound…
Thin Wall Investment Casting: Design, Limits & Uses TL;DR: Thin wall investment casting produces lightweight thin wall castings with sections down to about 1 mm. It suits thin section casting aerospace parts where weight and complexity are critical. Thin wall investment casting produces strong, light parts with very thin sections.…
Aerospace Bracket Casting: Structural Fittings Guide TL;DR: Aerospace bracket casting produces structural brackets and fittings to near-net shape, cutting machining and material waste. Cast in titanium, aluminium, or 17-4 PH, with HIP and NDT for load-bearing parts. Aerospace bracket casting turns complex mounting brackets into near-net-shape parts. Compared with machining…
First Article Inspection Aerospace Casting: AS9102 TL;DR: First article inspection aerospace casting is a full verification of the first production casting against its drawing and specification, documented on AS9102 forms. It is required before an aerospace part enters series production. First article inspection aerospace casting proves that a new casting…
Surface Finishing Aerospace Castings: Methods Guide TL;DR: Surface finishing aerospace castings turns an as-cast part into a functional finish. Investment casting starts around Ra 1.6 to 3.2 micrometres, improved further by shot blasting, machining, polishing, or anodizing. Surface finishing aerospace castings sets both appearance and performance. Good surface finishing aerospace…
Compressor Impeller Casting: Aerospace Process Guide TL;DR: Compressor impeller casting produces the rotating bladed wheel that raises pressure in a centrifugal compressor. Investment casting forms the complex blades to near-net shape in titanium, aluminium, or superalloy. Compressor impeller casting makes the bladed wheel at the heart of a centrifugal compressor.…
Passivation Stainless Steel Casting: Aerospace Guide TL;DR: Passivation stainless steel casting is a chemical treatment that removes free iron and boosts the chromium-oxide layer, giving aerospace castings full corrosion resistance. It follows AMS 2700 using nitric or citric acid. Passivation stainless steel casting is the finishing step that unlocks corrosion…