Products


Technical Design Data

Cast Alloys

HTCI can meet the requirements of the majority of material specifications available, including MIL-A-21180.

Aluminum Alloys
 A356A357535 (Almag 35)
 C355RR-350D712 (40E)

Tolerances

Normal cast tolerances are ± 0.01 for the first inch and then ± 0.005 inch per inch thereafter.

Because cost increases in proportion to dimensional requirements, it is important that tight tolerances be assigned to functional areas and other tolerances be generous to obtain the most economical design.


Mold Processes

HTCI, Co. offers the following types of molding processes in the production of our castings:


Plaster Mold

HTCI's ability to use the plaster mold process is unique in the industry. We have perfected this process to provide precision castings for aerospace, automotive, and other commercial needs.

Process

Tooling

Patterns are built out of water resistant materials, such as urethane, and mounted on cope and drag plates. Core boxes are developed when required from the same materials.

Plaster Mold

Once the patterns are created, they are set-up as needed and a specially formulated plaster slurry is poured over them to form the upper and lower mold portions.

Cores

If the part requires cores (to create passageways, etc.), a special plaster slurry is poured into a core box. When the plaster hardens, the core is removed from the box.

Mold Assembly

Mold sections and cores are assembled to create the complete mold. This mold is then baked in ovens to remove any moisture from the mold.

Pouring Metal

After bake-out, molten metal is poured into the molds.

Plaster Removal

After the metal has solidified and cooled, the molds are broken away by vibration or high pressure water blasts. The castings are then cut from the gate and deburred.


Solid Mold Investment

Solid mold investment is an economical way to produce high quality castings using a wax pattern.

Process

Tooling

Metal dies, usually aluminum, are produced from the customer's specifications.

Wax Injection

High pressure injection systems fill the cavity in the dies with wax, producing a pattern.

Assembly

Wax patterns are attached to gating (flow channels) and mounted to an aluminum plate.

Plaster Slurry

Plaster slurry is poured over the wax pattern in a vacuum chamber to form a mold.

Burn-Out

After the molds are created, the wax is melted out using a gas-fired dewax furnace.

Pouring Metal

The "void" left by the wax will be filled by molten metal.

Plaster Removal

After the metal has solidified and cooled, the molds are broken away by vibration or high pressure water blasts. The castings are then cut from the gate and deburred.


Precision Sand

Precision sand is an effective way to produce high quality castings using a no-bake sand mold.

Process

Tooling

Patterns are built using urethane tooling. Core boxes are developed when required.

Sand Mold

Once the patterns are created, sand is mixed via an automatic mixing system using a specific percentage of airset binder. They are set-up as needed and the sand mixture is poured in them to form the upper and lower mold portions.

Cores

If the part requires cores (to create passageways, etc.), core blowing machines blow sand into core boxes. The machine has a mixture of sand and chemical hardener that allows the sand to harden quickly.

Mold Assembly

Mold sections and cores are assembled to create the complete mold.

Pouring Metal

The molten metal is poured into the molds.

Sand Removal

After the metal has solidified and cooled, the molds are broken away by vibration. The castings are then cut from the gate and deburred.


HTCI, Co.
12170 Milton-Carlisle Rd.
New Carlisle, OH 45344
937-845-1204