The CAST-IT application engineers have compiled their collective knowledge on the following topics:
In-Process Weld Rework Reduces Cost and Lead Time for Aluminum Castings
In-Process Weld Rework (I-PWR) is an everyday metalcasting industry finishing process that reworks indications of potential non-conformances. This process is often unnecessarily limited which results in an increase in cost and lead times. In 2018, AMC published a Casting Quality Tip on I-PWR in hopes of increasing the understanding and acceptance of this procedure for defense castings. Using the Casting Quality Tip as well as other supporting data, David Weiss, VP of Sales and Engineering at Eck Industries, was able to convince his customer to overturn a blanket specification banning I-PWR.
Internal scrap rate in a metalcaster’s shop is a major concern for casting producers and customers. Pragmatic approval of in-process weld rework, as one of the many normal casting finishing processes, has the potential to drive down the internal scrap rate and the resulting high casting costs and lead times.
Solutions to assist in the FAT process to avoid delays or additional testing costs to best enable a responsive supply chain to support defense procurements, minimize PLT and reduce impacts on stock availability.
The casting process has nearly unlimited flexibility compared to other manufacturing processes and is excellent for optimizing designs based on performance and weight requirements rather than processing limitations.