Grain Structure and Refinement

Examines the casting's grain structure, assessing grain size, shape, and distribution to ensure material strength and uniformity.

Centrifugal Casting Services

Frigate excels in centrifugal casting and finish machining high-grade ferrous and non-ferrous products. Our components are used in various applications, including steel mills, power transmission lines, and elevators. We deliver precision and durability in every cast. Trust Frigate for superior quality and performance in your industrial needs.

Our Clients

Advantages of Centrifugal Casting with Frigate

Superior Density and Strength

Centrifugal casting services produces components with a higher density and greater strength due to eliminating impurities and gas bubbles.

Enhanced Structural Integrity

The process ensures uniform grain structure, reducing the defect risk and enhancing the cast parts' overall structural integrity.

Improved Material Properties

Centrifugal casting allows for better control over the alloy composition, resulting in improved mechanical properties and increased wear resistance.

Reduced Waste

This method produces minimal waste material, making it more cost-effective and environmentally friendly.

Frigate's Approach to Centrifugal Casting

Centrifugal casting service is perfect for creating thin-walled cylinders. We use one die to produce items of the same size with different wall thicknesses. At Frigate, we work with various metals and alloys, including exotic high-strength, high-temperature materials. Precise control of metallurgy and grain structure ensures sound castings with smooth surfaces. The result? Excellent strength and toughness.

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Our Centrifugal Casting Process

Mold Preparation

A cylindrical mold is selected or created based on the desired dimensions of the final product. The e molds are typically made from steel or other durable materials to withstand high temperatures.

Preheating the Mold

To avoid thermal shock when molten metal is added, the mold is prepared to a certain temperature. This step also helps achieve better surface quality and reduce defects.

Pouring the Molten Metal

Molten metal or alloy is poured into the rotating mold. The mold is spun quickly, usually on a horizontal or vertical axis. The molten metal is forced up against the mold's inner walls by the centrifugal force created by this spinning.

Forming the Casting

As the mold spins, the centrifugal force ensures that the molten metal fills the cavity uniformly, forming a dense and homogenous casting. Any impurities or inclusions are pushed towards the center, where they can be machined out later.

Cooling and Ejection

Once the metal has fully solidified, the mold is stopped, and the casting can cool further. The casting is then ejected from the mold.

Finishing

To get the final specifications and intended qualities, the cast part is put through a variety of finishing procedures, including machining, heat treatment, and surface treatments.

Centrifugal Casting Materials

Our expertise in metallurgy and grain structure control guarantees that each casting we produce has the strength, durability, and precision our clients expect.

Carbon Steel

Known for its durability and versatility, carbon steel is a fundamental choice for many applications. It provides a good balance of strength and toughness, making it suitable for various industrial uses.

Stainless Steel

Offering excellent corrosion resistance and strength, stainless steel is ideal for environments that require high durability and cleanliness. It's commonly used in the food, pharmaceutical, and chemical industries.

Alloy Steel

Alloy steel includes a variety of metals that enhance its mechanical properties. These steels are ideal for demanding applications because of their exceptional strength, toughness, and wear resistance.

Copper Alloys

Alloys, such as bronze and brass, are valued for their excellent electrical & thermal conductivity and resistance to corrosion. They are often used in electrical components and plumbing fixtures.

Nickel Alloys

They are renowned for their ability to withstand high temperatures and corrosive environments. They are often used in aerospace, chemical processing, and power generation industries.

Aluminum

Lightweight and highly machinable, aluminum is a popular choice where weight reduction is crucial. It also offers good corrosion resistance and excellent thermal and electrical conductivity.

Titanium

Titanium is well known for having a high strength-to-weight ratio and an outstanding resistance to corrosion. It's used in aerospace, medical implants, and marine applications where performance and longevity are critical.

Superalloys

Superalloys are designed to maintain strength and stability at extremely high temperatures. They are essential in aerospace, gas turbines, and other high-performance industries.

Custom Centrifugal Casting Solutions at Frigate

Centrifugal casting allows us to create pieces tailored to each part’s needs. Without cores, we can produce items of any length, thickness, or diameter. This method ensures parts have rotational symmetry due to gravity, resulting in seamless and large-size components. The production cost is low because molds can be reused for parts with varying wall thicknesses. This casting is less appropriate for pieces that need unique shapes because it is usually used to make stock materials. Only cylindrical shapes can be made, and there may be a considerable wait time.

Compliance for Centrifugal Casting Services

Frigate adheres to the highest industry standards for Centrifugal Casting, ensuring products meet all necessary technical and safety specifications. Our centrifugal casting processes follow rigorous material and production requirements to achieve exceptional strength, precision, and durability. We maintain certifications from globally recognized bodies, guaranteeing that each component we produce fully complies with all regulatory and environmental standards.

ASTM A532

Standard Specification for Wear-Resistant Cast Irons, ensuring high material quality and wear resistance.

ISO 9001:2015

Quality Management Systems certification for consistent and high-quality manufacturing practices.

ISO 14001:2015

Environmental Management certification, ensuring compliance with global environmental standards.

REACH (EC 1907/2006)

Compliance with the European Union regulation for the safe use of chemicals and materials.

RoHS (2011/65/EU)

Restriction of Hazardous Substances directive for environmental safety in electronic components.

AS9100D

Aerospace Quality Management System certification, meeting the aerospace industry's stringent requirements for safety and quality.

NADCAP

Accreditation for aerospace and defense processes, ensuring consistent quality in high-performance castings.

OSHA

Compliance with Occupational Safety and Health Administration regulations to maintain safe working conditions.

Tolerance for Centrifugal Casting Services

Dimensional Accuracy

±0.5 mm to ±3.0 mm

Precision tolerance for diameters, lengths, and overall dimensions, ensuring tight fits and assembly.

Wall Thickness

±1.0 mm

Variations in wall thickness that ensure consistent material strength and structural integrity.

Concentricity

≤ 0.5 mm

Deviation from the ideal concentric alignment between the inner and outer diameters to ensure proper fit in assemblies.

Roundness

±0.3 mm to ±1.0 mm

Circularity tolerance affecting rotational performance and sealing applications.

Surface Finish

Ra 1.6 µm to Ra 3.2 µm

Measurement of the surface roughness, critical for friction, corrosion resistance, and visual quality.

Straightness

≤ 0.5 mm per meter

Deviation from a straight line, ensuring optimal assembly and functionality.

Hardness

±5-10 HB (Brinell Hardness)

Hardness tolerance that affects wear resistance and material strength, crucial for high-stress environments.

Weight Consistency

±0.5% to ±2.0%

Weight variation tolerance, ensuring consistent material distribution and density for uniform performance.

Radial Thickness Variation

≤ 2.0 mm

Tolerance for the variation in radial thickness across the casting, ensuring uniform strength and material properties.

Core Shifting

≤ 1.0 mm

Deviation in core placement, affecting internal geometry and fluid flow in applications like pumps or pipes.

Casting Porosity

≤ 1%

Tolerance for the porosity level, affecting structural integrity and material strength.

Surface Defects (Cracks, Voids)

≤ 0.1%

Tolerance for casting defects, ensuring minimal impact on the structural performance and aesthetics.

Internal Diameter Tolerance

±0.5 mm to ±2.0 mm

Precision in the internal diameter to ensure proper assembly with other components, especially in pipe fittings and bearings.

Shrinkage

±1% to ±2%

Tolerance for material shrinkage during cooling, ensuring dimensional consistency and fitting precision.

Thermal Expansion

≤ 0.0001 mm/°C

Allowance for thermal expansion, critical for high-temperature applications such as exhaust systems.

Microstructure Uniformity

ASTM A 128 Class III

Standard for ensuring uniform distribution of grains in high-performance castings, improving mechanical properties.

Casting Perpendicularity

≤ 0.5 mm

Deviation from a perpendicular angle between surfaces, important for assembly and function in geometrically critical parts.

Vibration Resistance

Vibration Frequency: ≤ 50 Hz

Specific tolerance for vibration absorption, vital in high-performance applications like engine components.

Quality Testing Standards for Centrifugal Casting Services

Dimensional Tolerance

CMM (Coordinate Measuring Machine), Optical Comparator

Ensures the casting dimensions, including diameters, lengths, and wall thicknesses, are within specified tolerances.

Centrifugal Casting Bonding

Metallographic Analysis, X-ray Imaging

Verifies proper bonding between different layers of material in multi-layer castings to prevent delamination.

Thermal Conductivity

Hot Disk Thermal Conductivity Measurement

Measures the thermal conductivity of the material, ensuring that castings perform optimally under heat-exposed conditions.

Microhardness Mapping

Knoop or Vickers Microhardness Test

Provides detailed hardness measurements across the surface, ensuring material consistency and strength.

Density & Porosity

Archimedes Principle or X-ray CT Scanning

Measures casting density and checks for internal porosity, ensuring the material integrity and strength are not compromised.

Creep Resistance

Creep Test (ASTM E139)

Measures the casting's ability to resist deformation under prolonged stress, crucial for high-temperature applications.

Casting Shrinkage

Direct Measurement or Analytical Prediction

Measures dimensional changes during solidification to anticipate and compensate for shrinkage during cooling.

Radial Stress Distribution

Finite Element Analysis (FEA), Strain Gauges

Analyzes the distribution of stress within the casting, ensuring uniformity and preventing failure under operational loads.

Concentration of Alloying Elements

Optical Emission Spectroscopy (OES)

Quantifies the concentration of alloying elements to confirm compliance with material specifications and desired properties.

Cyclic Loading and Fatigue

Rotating Bend or Axial Load Fatigue Testing

Evaluates casting’s ability to withstand repeated loading conditions, crucial for parts subjected to dynamic forces.

Climatic Testing

Thermal Cycling, Humidity Exposure

Simulates environmental stress, ensuring castings perform under varying temperature and moisture conditions.

Soundness Testing

Acoustical Testing or Ultrasonic Testing

Detects casting defects like cracks, voids, or inconsistent material flow, ensuring a high level of casting integrity.

Yield Strength

Tensile Test (ASTM E8)

Measures the yield strength, providing information about the material’s ability to resist permanent deformation under stress.

Magnetic Permeability

Magnetization or Eddy Current Testing

Assesses the material’s ability to conduct magnetic fields, important for applications in motors, transformers, and sensors.

Corrosion Resistance

Salt Spray Test (ASTM B117)

Evaluates the casting's resistance to corrosion in salt-laden environments, crucial for automotive and marine applications.

Electromagnetic Compatibility (EMC)

EMI Testing (Electromagnetic Interference)

Ensures that castings used in electronics or aerospace applications meet electromagnetic compatibility standards.

Unlock the Advantages of Centrifugal Casting with Frigate

Our centrifugal casting process offers a range of benefits that enhance your project’s outcomes. This method produces cast parts with finely compacted metal grains, resulting in superior strength and corrosion resistance. This not only improves machining and finishing but also reduces rejection rates.

Our process integrates seamlessly with automation, allowing precise control over molten metal preparation, pouring speed, and mold rotation, which ensures consistent, high-quality castings. Additionally, centrifugal casting’s versatility enables the production of symmetrical castings in various diameters and lengths, exhibiting excellent mechanical properties. Trust Frigate to leverage these advantages for reliable, high-performance components tailored to your needs.

Industries We Serve

What You Get

Centrifugal Casting for Automotive Excellence

We understand the demands of the automotive industry for precision and durability. Our centrifugal casting services are designed to meet these needs by producing metal parts with exceptional accuracy and superior surface finish. We specialize in creating components with intricate designs and thin wall sections crucial for automotive applications. Our process ensures high dimensional precision and excellent purity, translating to reliable performance and reduced production costs.

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What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What is the role of centrifugal force in centrifugal casting?

Centrifugal force helps to push molten metal against the mold wall during casting. This force creates a strong, dense material and reduces the chances of defects like porosity. The faster the mold spins, the greater the force, which improves the quality of the final product.

How does the cooling rate affect the properties of centrifugal castings?

The cooling rate in centrifugal casting is crucial. Faster cooling can lead to finer grain structures, which enhance strength and hardness. Slower cooling can result in larger grains, affecting toughness. Controlling the cooling rate helps achieve the desired material properties for specific applications.

What types of molds are used in centrifugal casting, and how do they impact the process?

Centrifugal casting uses two main types of molds: permanent and expendable. Permanent molds are metal and can be reused, while expendable molds are made from materials like sand. The choice of mold affects the surface finish and dimensional accuracy. Metal molds generally provide better precision.

Why is it important to consider the metal’s viscosity during centrifugal casting?

The viscosity of molten metal affects how well it fills the mold. Low-viscosity metals flow easily, ensuring complete mold filling and better details. High-viscosity metals may struggle to fill the mold, leading to defects. Selecting the right metal and temperature is essential for a successful casting.

How can centrifugal casting be used for complex shapes or thin-walled components?

Because of the centrifugal force, centrifugal casting is effective for creating complex shapes and thin-walled components. As the mold spins, the molten metal helps fill intricate details. This method allows for precise control over wall thickness, making it ideal for parts like pipes and tubes.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ