"TEKCAST" - technology of centrifugal casting to the TEKSIL´s moulds

SERVICE

• casting design (prototype and also series product)
• production of patterns from metal and plastic
• production of castings from zinc alloy
• preparation of surface treatment of castings
• consulting service

Nontraditional technology of centrifugal casting offers higher duality in the sphere of strength of materials, accuracy of castings and better reproduction of casting detail and embossment from noncommercial zinc alloys.

The principle of technology is based on casting pattern cast (eventually enlarged by surplus additions for shrinkage owing to melting cooling) to the moulding material “TEKSIL” and its vulcanization.

The advantages of technology are incomparably lower economic costs on the production of components, which are alternatively produced by casting under pressure to the metal moulds or by cutting operation, high time and labour savings. The path from the pattern to the casting lasts about several hours.

The pattern, its appropriate design and surface quality is prerequisite to reach maximal lifetime of the moulds and required quality of castings. It is possible to make the pattern by cutting operation and polishing its surface (for machine-technological and constructional castings, preferably from aluminium or brass alloys, but also from steel), or by cutting operation on the milling plotter in co-operation with graphic PC-program (for decorative casting with embossment from the special plastic), or it is possible to use original part from appropriate material as the pattern, if technological conditions of the production allow it.

The mould from TEKSIL´s rubber (silicone-based) enables the production of castings in appropriate accuracy, strength, quality of detail and surface, within her relatively long-lasting, but limited lifetime. The maximal sizes and weight of casting are due to the size of vulcanizer and frames for the production of moulds (100 x 200 mm, height up to 65 mm, weight up to 1,5 kg). The lifetime of the mould is due to complication of the casting shape, to its size, to removable cavity of the mould and related influences of technological process (10 - 200 casting cycles = 10 - 4.000 pcs of castings / 1 mould).

The casting, made from a commercial zinc alloy Z 430 (ZnAl4Cu3 - CZN 42 3562), as a standard type, is dimensional accurate in appropriate way, surface-clean and quality. Mechanical characteristics - tensile stress resistance Rm - 215 MPa, tensibility A5 - 0,5 to 2%, lowest Brinell hardness - 90 HB, yield limit Rp - inf. 170 to 200 MPa, specific weight - 6,9 g/mm2. It is possible to realize no-demountable connection of casting with a component from other metal- e.g. splash with brass bush, screw, pin, little axis from steel et al.. Castings are finished by machine (eventually by hand) after their casting and cooling - intake, divisional plane (event. defect of detail). Finishing process of casting surface is made by technology of vibratory rehashing of casting in technological machinery with a filling of ceramic corpuscles, water and detergent.

Surface treatment (if casting needs it) is possible either by electro-galvanizing of casting with mass method (drum-type), or piece method (suspension), in wide range of design possibilities, or e.g. electro-static coating of paint powder with follow up hardening of powder layer in the baking kiln, also in wide range of design.

The possibilities of technology cover the production of castings with character - piece of machinery (connecting and assembling parts, technological and machine elements, cases, boxes, body shells, handles, levers, holders, racks, keys, controls et al.), with promotion character, advertising, imitation jewellery and gift items (drops, medals, plaquettes, labels, clips, fasteners, statuettes and little figures et al.). It is possible to attest function, strength, design and surface quality of prototype series castings in the sphere of prototype production, at low costs.

The price of the casting is approximately 300 - 500,- CZK/kg. The price per piece for series orders is calculated on basis of realization of testing series and production of test casting.