In the previous article, we described the different types of chaplets and foundry consumables. However, we didn’t focus on a key aspect: how do you choose the most suitable support based on the specific characteristics of the casting?
In this regard, the complexity of foundry processes and numerous, often hard-to-control variables make thorough analysis and personalized evaluation of all influencing parameters essential. We can effectively meet specific production needs only through tailor-made solutions, ensuring optimal and reliable results.
For this reason, at Vemek, we develop customized chaplets and foundry supports, tailored through careful analysis to define specific requirements and provide the most suitable components for every situation, regardless of the casting type.
In this article, we’ll explain what customized foundry consumables means and why tailor-made small metal parts are the ideal solution for foundries in terms of performance, reliability, and results.
The importance of customizing foundry consumables
A modern casting process requires advanced machinery, high-quality materials, and significant resources. However, in this context, the role of the consumable is often underestimated: it is frequently treated as a mere accessory. Unfortunately, this leads to using standardized components, often selected by the manufacturer, which may be cost-effective but deliver inadequate performance. Suboptimal shapes and sizes that can compromise the entire process are among the main limitations.
However, the described approach is based on a flawed assumption: despite their size and cost, chaplets play a key role in determining the success or failure of the casting process. As a result, it is essential to dedicate time and attention to the customization of supports from the earliest stages of casting design.
Factors to consider when choosing a foundry chaplet
What are the real risks of using a non-customized or unsuitable chaplet? Numerous variables influence the success of a casting, and each one can have a significant impact.
The chaplet must balance two fundamental (and often conflicting) requirements: on one hand, it must be robust enough to withstand metallostatic pressure without deforming during pouring; on the other, it must avoid excessively cooling the casting, to ensure perfect fusion with the molten metal.
Factors such as pouring speed and temperature, the position of the gating system, and wall thickness directly affect the effectiveness of the chaplet. If placed near the ingate channels, it will be exposed to high temperatures for extended periods and must therefore be dimensioned accordingly. Conversely, in areas with thin walls, it must be carefully calibrated (reduced) to avoid unwanted heat loss.
Fastening also plays a key role: a poorly positioned chaplet can shift during pouring, compromising the final result. That’s why tailor-made solutions are available, including self-adhesive chaplets, anchoring nails, or anchoring clip profiles that perfectly adapt to the shape of the core.
Each chaplet is coated with a thin layer of pure tin (just a few microns thick) applied through electrolytic deposition. In addition to preventing oxidation, this treatment promotes perfect integration with the casting, eliminating the risk of bubbles and unwanted voids.
The risks of using an inadequate chaplet
An inadequate chaplet can cause defects in castings, leading to the need for rework or, in more critical cases, the part rejection.
If the chaplet is not precisely designed, the casting dimensions may differ from the intended specifications due to core displacement during pouring. This issue can arise in two cases: when the chaplet is insufficient and when it fails to maintain its designated position.
A chaplet that does not properly integrate with the molten material and remains as a foreign body, can compromise the integrity of the casting, leading to leakage issues.
In the foundry industry, the use of core support chaplets has been a well-established practice for decades. For every specific application, there are engineered solutions that ensure operational safety and optimal performance.
Each consumable can be adapted and customized to meet the specific requirements of the casting, ensuring high-quality results and reducing the risk of faults.
Customized chaplets: the details that make the difference
At Vemek, we have always embraced a working approach focused on the design and production of customized chaplets. For over 60 years, our engineers have worked in close collaboration with some of the world’s most advanced foundries, gaining top-level know-how, and are ready to be shared in the development of future projects.
The concrete realization of each piece is only the final step of a process that involves analysis, field research, testing, and consulting. Every phase is carried out alongside the customer, who, according to our vision, is an integral part of the development and engineering process of each component.
The final result consists of tailor-made chills and chaplets, specifically created for each case. Perfectly aligned with the specific needs of the production system, they are safe, reliable, and essential for minimizing risks and unforeseen issues.
Want to learn more or request a customized quote? Contact us via our form or by phone: we’ll be glad to show you how we can enhance your foundry’s performance!