CASTINGS FROM NON-FERROUS METALS

Technical capabilities

Materials:

• Non-ferrous casting alloys, including bronzes and brasses.

Casting weight:

• from 0.5 to 120 kg.

Manufacturing processes:

• Casting in moulds made from cold-setting, self-hardening mixtures.
• Casting in sand moulds.

Additional operations:

• Design and manufacture of foundry pattern equipment and other tooling.
• Casting cleaning and removal of gating systems and risers.
• Heat treatment.
• Turning of castings, milling, drilling and boring.
• Verification of chemical composition, geometric dimensions and mechanical properties.
• Non-destructive testing in accordance with the requirements of the technical documentation.

The specific alloy grades, casting method, dimensional tolerances, need for additional processing and inspection scope are determined during technical preparation of the order.

What products is non-ferrous metal casting used for

Bronze and brass castings are used in industrial machinery and equipment. Non-ferrous metal casting allows parts with complex geometries and the required performance characteristics to be produced, as well as several structural functions to be combined in a single part with a limited number of assembly joints.

Main product types:

• Reduction gearbox and drive housings — housings with seating surfaces, stiffening ribs and internal cavities.
• Pump and compressor housings — cast housings, covers, flanges and unit components.
• Bearing assemblies — housings, supports, bushings and structural components of mechanisms.
• Mechanical transmission parts — hubs, pulleys, rotors and other drive system components.
• Brackets and support components — mounting parts, fastening assemblies and structural equipment components.
• Parts for process equipment — covers, flanges, connecting elements and components for industrial installations.
• Spare parts for machinery — cast blanks and finished parts for the repair and modernization of industrial equipment.

The selection of alloy and manufacturing process depends on operating conditions, mechanical loads, accuracy requirements and the intended use of the part.

Advantages of non-ferrous metal casting

• Complex product geometry.
  The ability to manufacture parts with internal cavities, stiffening ribs, projections and changes in cross-section.
• Broad design possibilities.
  Casting brass, bronze and other non-ferrous metals using an appropriately selected manufacturing process allows parts of various shapes and applications to be produced.
• Reduced number of components.
  A cast part can combine several functional elements, replacing a structure made up of several parts.
• Efficient material use.
  Producing blanks with a shape close to the finished product allows the amount of machining to be reduced.
• Ability to achieve specified performance characteristics.
  The selection of material and manufacturing process allows requirements for strength, wear resistance, thermal conductivity and other properties to be taken into account.
• Good repeatability in series production.
  Using stable production tooling allows parts of the same type with controlled properties to be manufactured.
• Flexible production volumes.
  One-off production and small batches can be carried out using sand moulds, including moulds made from cold-setting, self-hardening mixtures.

Process limitations

The following characteristics must be taken into account when designing and manufacturing non-ferrous metal castings:

• Casting shrinkage.
  Shrinkage occurs during metal solidification and must be taken into account when designing the mould and gating and feeding system.
• Potential casting defects.
  Failure to follow manufacturing procedures may lead to porosity, cavities, non-metallic inclusions and cracks.
• Dependence of properties on the manufacturing process.
  Cooling rate, solidification conditions and pouring parameters affect the microstructure and properties of the casting.
• Design limitations.
  Wall thickness, smooth transitions, draft angles and mould filling conditions must be taken into account.
• The need for machining.
  Achieving accurate seating dimensions, holes and mating surfaces usually requires additional machining.
• Production tooling costs.
  The manufacture of patterns, core boxes and permanent moulds affects the cost of the order.
• Economic limitations for small batches.
  For some products, the cost of complex tooling may be disproportionate to the production volume.

Manufacturing non-ferrous metal castings

PRITZ DEVELOPMENT produces custom brass castings, as well as bronze and other non-ferrous metal castings, at specialized partner facilities. Production is carried out according to the customer’s drawings, 3D models and technical documentation.

The customer’s technical documentation forms the basis for casting quotations and production preparation. We analyze the design of the part to be manufactured according to the drawing, the material requirements and operating conditions, and then determine a suitable manufacturing process.

If necessary, foundry pattern equipment or permanent mould tooling is designed and manufactured taking into account casting shrinkage, draft angles and machining allowances.

Once the casting has been produced, cleaning and, if necessary, heat treatment can be carried out. Subsequent machining may include turning, milling of castings, drilling and boring.

Quality control is organized in accordance with the requirements of the technical documentation and may include verification of material properties, dimensional inspection and testing to detect casting defects.

Typical production process sequence:

Drawing analysis → Process selection → Tooling manufacture → Casting → Cleaning → Heat treatment → Machining → Quality control → Delivery of finished parts.

Why PRITZ DEVELOPMENT

Series production repeatability
Stability of dimensions, geometry and product quality across successive batches.

Full production cycle
Core metalworking operations are carried out within a single production process.

Working from customer documentation
Production is organized based on agreed drawings and technical requirements.

Production of pre-series batches
Before launching regular production, the manufacturing process and product can be checked using a limited batch.

ISO 9001
A quality management system with a valid certificate.

Headquarters in Poland
PRITZ DEVELOPMENT is headquartered in Katowice and focuses on cooperation with B2B customers in Poland and the EU.