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Aerospace Castings – Materials and Manufacturing Processes

Frigate’s expertise in aerospace castings, backed by a dedication to quality and innovation, we're here to help you stay ahead of the curve.

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In the Aerospace Industry, precision is the most important thing.  They should be lightweight. That’s what makes these marvels of flight function properly. But how does this function properly? The answer is components and aerospace castings. They are crafted with accurate precision. That is the ground point of this innovation.  

What are Aerospace Castings? 

Aerospace castings are a type of metal shaping process that utilizes molten metal poured into a mold to create complex, near-net shape parts. Investment casting, also known as lost wax casting, is a prevalent method. A wax pattern is meticulously created here to replicate the final part’s design. This wax pattern is then encased in a ceramic shell, and the wax is melted away, leaving a negative mold cavity. Molten metal, typically high-strength alloys, is poured into the mold and allowed to solidify, and the ceramic shell is broken away to reveal the final cast component. 

Aerospace Castings - Materials and Manufacturing Processes

Creating Aerospace Components Through Casting 

Aerospace casting is a versatile method for manufacturing various components essential for aircraft. Engine and fuel system parts are among the many components that can be efficiently produced through aerospace casting. However, it’s not just limited to engine parts. Many non-engine components find their origin in casting for aerospace use. These include cabin control systems, parts for hydraulic systems, environmental controls, landing systems, and various other internal mechanical parts. 

The flexibility and adaptability of casting make it a preferred choice across diverse aerospace applications. Its ability to cater to a wide range of component types while maintaining high quality and cost-effectiveness is unmatched. This efficiency in production translates to significant savings without compromising the integrity and performance of the components crucial for aircraft production. 

Why Choose Aerospace Castings? 

There are several reasons why aerospace castings are the go-to solution for many critical aircraft components: 

  • Complex Geometries – Investment casting excels at producing parts with complex features and internal channels, which is ideal for complex aerospace components like turbine blades and engine housings. 
  • LightweightAerospace prioritizes weight reduction. Castings, particularly those made from lightweight alloys like aluminum and titanium, contribute to a lighter aircraft, improving fuel efficiency and overall performance. 
  • Design Freedom – The lost wax process offers exceptional design freedom. Unlike machining or forging, complex shapes, and internal features are readily achievable, allowing for innovative and efficient designs. 
  • Near-Net Shapes – Castings produce parts close to their final dimensions, minimizing the need for extensive machining. This translates to lead time reduction and lower production costs. 
  • Strict Tolerances – Aerospace castings can be manufactured to meet strict tolerances, ensuring precise fit and function within critical aircraft systems. 
Aerospace Castings parts

Materials for Aerospace Castings 

The success of an aerospace casting hinges on material selection. Here are some of the most used high-strength alloys for aerospace castings: 

Aluminum Alloys – Offering a good balance of strength, weight, and affordability, aluminum alloys are popular for airframe components and engine parts. 

Titanium Alloys – Renowned for their exceptional strength-to-weight ratio and high-temperature resistance, titanium alloys are ideal for engine components and landing gear. 

Nickel-Based Alloys – These alloys excel in high-temperature environments and resist corrosion, making them perfect for turbine blades and exhaust components. 

Stainless Steel – Offering a combination of strength, corrosion resistance, and affordability, stainless steel is used in various aerospace applications. 

Aerospace Castings materials


Meeting the Demands of the Aerospace Industry 

In the aerospace industry, excellence is not just a goal; it’s a requirement. That’s why Frigate offerings go above and beyond. We provide accuracy in delivering quality, precision, and reliability with every aerospace casting we produce. Our state-of-the-art facilities boast cutting-edge CMM and VMM capabilities, allowing us to achieve tolerances of up to 1 micron with unparalleled accuracy. 

With a capacity of up to 400 tons, we can accommodate projects of any scale. Our commitment to meeting industry standards ensures compliance with the most stringent regulations and specifications. From customized cables and wires to hoses and beyond, our comprehensive range of offerings has everything you need to take your aerospace applications to new heights. 

Beyond Castings – Your One-Stop Shop for Aerospace Manufacturing 

At frigate, we understand the critical role of aerospace castings. We offer a comprehensive suite of services beyond just castings to cater to your specific needs. This includes: 

  • Precision Machining – For parts requiring tight tolerances and intricate features beyond casting capabilities, our precision machining services ensure perfect finishing touches. 
  • Forging – For components demanding exceptional strength and impact resistance, our forging capabilities can deliver. We offer forging services for aluminum, copper, and various other alloys. 
  • Customized Cables & Wires – We can design and manufacture custom cables and wires to meet the specific electrical and mechanical requirements of your aerospace application. 
  • CMM Inspection – Our Coordinate Measuring Machines (CMM) provide high-precision dimensional analysis, guaranteeing your castings meet the strictest tolerances. 
  • Hoses: We offer a wide variety of hoses suitable for various aerospace applications, ensuring proper fluid flow and system operation. 

Elevate Your Aerospace Operations with Frigate 

With Frigate’s expertise in aerospace castings, backed by a dedication to quality and innovation, we’re here to help you stay ahead of the curve. Whether you need precision machined aluminum parts or customized bronze forgings, we have the capabilities and commitment to bring your aerospace vision to life. 

So, if you’re ready to elevate your aerospace operations to new heights, look no further than Frigate. We are dedicated to providing the aerospace industry with the highest quality castings and manufacturing services. Contact us today to discuss your specific requirements and how we can help your project take flight. Together, let’s soar toward a future of innovation and excellence. 

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