{"id":13100,"date":"2025-12-16T05:06:45","date_gmt":"2025-12-16T03:06:45","guid":{"rendered":"http:\/\/vemek.it\/?p=13100"},"modified":"2025-12-16T11:36:02","modified_gmt":"2025-12-16T09:36:02","slug":"how-the-quality-of-precision-metal-parts-helps-reduce-casting-waste","status":"publish","type":"post","link":"https:\/\/vemek.it\/en\/how-the-quality-of-precision-metal-parts-helps-reduce-casting-waste\/","title":{"rendered":"How the quality of precision metal parts helps reduce casting waste"},"content":{"rendered":"

In the foundry industry, the term scrap \u2013 or casting waste \u2013 refers to metal material that cannot be used, resulting from a casting or machining process that failed to meet the required specifications. There are many reasons why a casting may generate scrap: incorrect temperature, metal impurities, mold defects, or issues in material handling.<\/p>\n

In this article, we focus on an often-overlooked yet crucial factor: the use of high-quality precision metal parts (core supports)<\/strong> that are preferably custom-made for the specific application. Components like core supports, spacers, or mold locators<\/strong>, when carefully designed and manufactured, play a key role in ensuring the stability of the casting process<\/strong>, helping to minimize defects and, as a result, reduce scrap.<\/p>\n

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Defective\u00a0<\/span>c<\/span>astings<\/span><\/h2>\n

As one might expect, every foundry aims to\u00a0<\/span>minimize the number of defective\u00a0castings<\/span><\/b>\u00a0(the ones that\u00a0don\u2019t\u00a0conform to specifications).\u00a0A casting\u00a0is considered nonconforming when the final product\u00a0doesn\u2019t\u00a0meet the project\u00a0requirements, such as dimensions, tolerances, or material properties.<\/span>\u00a0<\/span><\/p>\n

There are multiple causes that can lead to scrap: temperature errors, metal impurities, mold defects, or issues in material handling.<\/span><\/p>\n

In particular, the risk of producing nonconforming castings\u00a0<\/span><\/span>increases with the pressure exerted by the molten metal on the mold walls and on the cores<\/span><\/span><\/strong>.<\/strong> This is especially true for\u00a0<\/span><\/span>pressure-tight castings<\/span><\/span><\/strong>, where the\u00a0<\/span>component<\/span>\u00a0must guarantee extremely high sealing performance. In such cases, even the smallest imperfections can result in a higher scrap rate.<\/span><\/span>\u00a0<\/span><\/p>\n

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The impact of foundry supports on scrap casting<\/span><\/span><\/h3>\n

The\u00a0<\/span>supports\u00a0used to hold cores in place<\/span><\/b>\u00a0during foundry processes play a decisive role in the success of the casting. If the metal\u00a0component\u00a0is unsuitable, the support itself may fail, leading to serious issues\u2014first and foremost, the undesired displacement of the cores.\u00a0As a result, the final casting may fall outside the required tolerance range (that is, beyond the acceptable margin of error), or leakages may occur if the support is not properly integrated, allowing fluids to escape from the\u00a0component.<\/span>\u00a0<\/span><\/p>\n

Each of these scenarios leads to the same outcome: a casting that generates scrap material. How can these issues be prevented? Quite simply, by investing in the\u00a0<\/span>production of high-quality precision metal parts<\/span><\/b>\u2014and, more specifically, by designing\u00a0<\/span>custom-made supports<\/span><\/b>\u00a0engineered and manufactured for the specific application.<\/span>\u00a0<\/span><\/p>\n

\"Supporto<\/a>
Foundry support not optimized<\/em><\/figcaption><\/figure>\n

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Choosing the spacer: an example of\u00a0<\/span>apparent<\/span>\u00a0savings and hidden costs<\/span>\u00a0<\/span>\u00a0<\/span><\/h2>\n

A foundry partnered with\u00a0<\/span>Vemek<\/span><\/b>\u00a0to develop\u00a0<\/span>a\u00a0separator\u00a0designed to\u00a0maintain\u00a0a constant distance between the water jackets of an engine<\/span><\/b>. The client\u00a0had to\u00a0take a decision:\u00a0<\/span>\u00a0<\/span><\/p>\n

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  1. A standard support<\/span><\/b>, more affordable, but whose correct positioning depended entirely on the operator\u2019s strength and precision.<\/span>\u00a0<\/span><\/b>\u00a0<\/span><\/li>\n<\/ol>\n
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    1. A custom-made support<\/span><\/b>, slightly more expensive, but engineered to\u00a0<\/span>ensure perfect positioning and greater resistance<\/span><\/b>\u00a0to the pressure of molten metal.<\/span>\u00a0<\/span><\/li>\n<\/ol>\n

      The client chose the first\u00a0option, aiming for immediate cost savings. However, during production, a problem quickly\u00a0emerged<\/span>: the support was often positioned incorrectly<\/span><\/b>, compromising the proper alignment of the water jackets.<\/span>\u00a0<\/span><\/p>\n

      To solve the problem,\u00a0<\/span>the foundry had to install a highly specialized robot<\/span><\/b>\u00a0to check the height of the\u00a0distance\u00a0spacer and ensure it was correctly positioned inside the core. This intervention resulted in\u00a0<\/span>significant\u00a0additional\u00a0costs<\/span><\/b>\u00a0and\u00a0greatly increased\u00a0the complexity of the production process.<\/span>\u00a0<\/span><\/p>\n

      If the client had chosen the\u00a0<\/span>custom-made support<\/span><\/b>, the\u00a0additional\u00a0investment of just a few cents per piece would have resulted in\u00a0the following benefits:<\/span>\u00a0<\/span><\/p>\n