Castings

Whatever size casting you require, we are confident that we can obtain a competitive quote. we work with a wide range of manufacturers across the globe from the UK to China ensuring we can offer you processes as diverse as 110 tonne Iron Sand Casting to minute Investment Casting

Choosing the correct casting technique for a component given its material, size, complexity, quantity requirements now or future forecast is the key to getting the "Best Value" from a process. Use our experience with manufacturers in the UK, Europe and Far East to bring the best results.

Almost all casting processes are available through RPA Components Ltd. Our specialized areas however are:

Investment Casting
Also known as Lost Wax Casting, we are able to produce Steel Castings up to 50kg per piece by this process utilising both ceramic shell & block (plaster) mould techniques.
Centrifugal Casting
Also known as rotocasting or spin casting.
Sand Casting
By hand, mechanised moulding and automated systems (DISA)

Other processes:

Continuous Casting
- particularly for copper and copper alloys
Shell Moulding
Ferrous & Non Ferrous Materials
Gravity Die or Permanent Mould
High Pressure Die Casting
Low Pressure Die Casting
Metal Injection Moulding

Case Study: Pump & Valve Manufacture

Near net shape parts in a variety of applications

Investment or Lost Wax casting foundries have for many years been supplied to the Pump & Valve manufacturing industries.

The ability to cast fine detail reduced machining time. The ability to produce low batch quantities in a variety of alloys from the same tooling offers the designer greater flexibility.

Composite Casting

High cost materials on less expensive substrates

A composite casting is created when it is composed of two different castable materials from our production programme and arranged as outer and inner layer (or inner coating).

Alternative production processes to achieve this affect are for example the welding resurfacing process on a roller body, pressing two cylinders into one another, or various coating techniques.

A great advantage of composite casting is the freedom of choice of the layer thicknesses, which can start from a minimum of 5mm and be as thick as 150mm.

During the casting process, the two materials are poured into the mould one after the other. Here, time and temperature must be strictly controlled to match the appropriate material characteristics and the solidification properties.

After the outer layer has already solidified except for a thin inner layer of approx 3 to 8mm wall thickness, the inner layer is cast at a precisely defined time and at the correct temperature. It will mix with the residual melt of the outer layer and continually solidify from the outside towards the inside.

Here, there are limitations with regard to the material combinations possible, since tensions created by differing solidification characteristics or changes in the two materials may be too great and lead to the formation of cracks.

Numerous applications have already been realised, for example for the sure application of hard wear layers on the outside or inside. The application of expensive materials such as nickel-based alloys on less expensive substrates, both inside and outside.

In the case of thick applied layers, it is thus an economical procedure, offering a very great degree of certainty with great flexibility as to layer thicknesses and the materials that can be used.

Centrifugal Castings for Rollers

High Grade Alloy Rollers

In recent years, we have been increasing employing our products on the sector of the larger rollers.

And this has taken place on the one hand with our long standing circle of customers, and on the other hand with new, and formerly completely unknown sectors of application.

As one of the reasons for this, we have been able to note a general change in the traditional markets. But as well as this, the ever increasing and stricter requirements made of our customers plant and machines make it more and more necessary to develop specific solutions, especially on the materials sector.

At present, the following dimension ranges are able to be manufactured.

Diameter up to approx 600mm in a length of up to 4500mm and diameter up to 1250mm in a length of up to 2500mm.

However, since these lengths are, in many cases, not sufficient we are able to produce tubes of up to approx 10 metres on our UP welding installation.

One example among many is the production of hollow rollers with a shaft passing through them, including both end pieces welded and finish machined, including balancing.

The rollers manufactured by us are employed in a great number of applications, such as bearing and support rollers for a wide range of processes for drying, cooling, crystallisation and the final shelling or peeling of food and chemical products or rollers used in the manufacture of flat glass, steel or paper.

Every case is unique and has its own special peculiarities and requiring its own specific solution. Together with our customers, we work out these solutions, and determine their practicability. For some applications, we would draw your attention here to our ability to produce compound castings. In this range of dimensions, a combination of two materials is also feasible, given the correct wall thickness proportions.

Especially the combination "soft inside - hard outside" offers great advantages with regard to the relatively simple machining of the inside diameter.

If you want any new design or construction, please contact us.

With our many years of experience, we will certainly also be able to offer you a complete solutions in many cases.

See more case studies