BCI Engineering

Castings and Forgings

An Overview of Capabilities
Last Updated: February 28, 2010
 Castings

BCI Castings and Forgings

 Types of Castings
! Gravity Castings
(Sand mold, permanent aluminum mold)
" The process by which molten metal is poured into a mold,
which contains a hollow cavity of the desired shape, and then
allowed to solidify.
" The solid casting is then ejected or broken out to complete the
process.
" From very small to very large.

! Die Castings
" The process of forcing molten metal under high pressure into
mold cavities (which are machined into dies).
" Small to medium in size; capable of high detail.

! Investment Castings--(Lost Wax/Loss Foam)

" The process of forming wax (or foam) into a shape, covering the
shape with sand and then pouring molten metal into the cavity
displacing the wax.
" Allows for high detail and dimensional accuracy.
" Generally small and medium size.

BCI Castings and Forgings

 Most Common Materials

! Grey Iron Castings

! Malleable Iron Castings
! Ductile Iron Castings
! Steel & Stainless Steel Castings
! Copper Castings
! Bronze Castings
! Brass Castings
! Aluminum Castings

BCI Castings and Forgings

 Malleable, Grey and Ductile Iron
! We use black and green sand molding, aluminum
molding, and lost-wax/lost foam methods
! Size from 0.1 kg to 8000 kg (3.5 oz to 9 tons)
! All ASTM grades available
! For higher quantity orders BCI can directly cast ASTM
grades; for lower quantity orders, conversion to
Chinese GB or Japanese JIS standards is often
necessary.)

BCI Castings and Forgings

 Steel and Stainless Steel
! We use black and green sand molding; aluminum
molding; die casting, lost-wax/lost-foam methods
! Sizes from 0.1 kg to 8000 kg (3.5 oz to 9 tons)
! All ASTM grades and alloys available
! (For higher quantity orders, BCI can directly cast ASTM
grades; for lower quantity orders, conversion to
Chinese GB or Japanese JIS standards is often
necessary.)

BCI Castings and Forgings

 Bronze, Brass and Copper
! We use sand molding; permanent molding; die casting
! Sizes from 0.1 kg to 500 kg (3.5 oz to 1/2 ton)
! All ASTM grades and alloys available
! (For higher quantity orders, BCI can directly cast ASTM
grades; for lower quantity orders, conversion to
Chinese GB or Japanese JIS standards is often
necessary.)

BCI Castings and Forgings

 Aluminum
! We use sand molding, aluminum molding, and die
casting methods
! Sizes from 0.1 kg to 1000 kg (3.5 oz to 1 ton)
! All ASTM grades and alloys available
! (For higher quantity orders, BCI can directly cast ASTM
grades; for lower quantity orders, conversion to
Chinese GB or Japanese JIS standards is often
necessary.)

BCI Castings and Forgings

 Heat-Treating
! Normalizing
" Reduces internal stresses and improves crystalline structure by application of
heat, maintaining temperature for appropriate duration, then slow cooling.
! Water and oil quenching
" Rapid cooling from elevated temperature to increase hardness and strength.
Often followed by tempering to restore some ductility (toughness).
! Tempering
" Reduces hardness and increases toughness by application of heat, maintaining
for appropriate duration, then controlled cooling.
! Surface Hardening
" Increases surface hardness of wear parts by engineered application of heat by
flame (flame hardening) or induction coils (induction hardening).

BCI Castings and Forgings

 Testing
! We can provide material certification for all castings:
" Chemical analysis
" Mechanical tests, including:
! Tensile strength/elongation
! Hardness testing

! We also provide Non Destructive Testing upon request:

" Dye penetration
" MPI
" UT
" X-ray

BCI Castings and Forgings

 Forgings

BCI Castings and Forgings

 Types of Forgings
! Impression Die Forgings
" Pounds or presses metal between two dies that contain a precut profile of the desired part.
" From 0.1 to 27,000 kgs (a few ounces to 60,000 lbs).

! Open Die Forgings

" Pounds between flat dies with no precut profiles in the dies. Movement of the work piece is
the key to this method.
" Shapes up to 91,000 kgs (200,000 lbs.) and 24 meters (80 feet).

! Seamless Rolled Ring Forgings

" Typically performed by punching a hole in a thick, round piece of metal (creating a donut
shape), and then rolling and squeezing.
" Up to 9 meters (30 ft) diameter.

! Cold Forgings
" Typically for smaller parts
" Including bending, cold drawing, cold heading, coining, extrusion, punching, etc

BCI Castings and Forgings

 Forged Materials Used By BCI
! Carbon, Alloy and Stainless Steel
" Most ASTM grades and alloys available
" (For higher quantity orders, BCI can directly cast ASTM grades;
for lower quantity orders, conversion to Chinese GB or Japanese
JIS standards is often necessary.)

! Aluminum
" Most ASTM grades and alloys available
" (For higher quantity orders, BCI can directly cast
ASTM grades; for lower quantity orders, conversion to
Chinese GB or Japanese JIS standards is often necessary.)

BCI Castings and Forgings

 Tuning and Finished Machining
! Can rough machine shafts up to 24 meters (80 ft)
" Can finish machine up to 14 meters (45 ft)

! Can rough machine donuts up to 9 meters (30 ft)

" Can finish machine up to 3.7 meters (12 ft) in diameter

BCI Castings and Forgings

 Surface Heat-Treating
! Flame hardening
" A process whereby a forging is exposed to an open flame and then
quenched (cooled in oil, water or air)

! Induction hardening
" The localized surface heating of a forging by an electrically-heated
induction coil

BCI Castings and Forgings

 Testing
! We provide material certification for all forgings in:
" Chemical analysis
" Mechanical tests, including:
! Tensile strength/elongation
! Hardness testing

! We also provide Non-Destructive Testing upon

request:
" Dye penetration
" MPI
" UT
" X-ray

BCI Castings and Forgings

Please Contact Us

Hong Kong

Tim Brantingham, Director, Asia-Pacific

" Phone: (852) 9278-5204
" Fax: (852) 2802-0861
" E-Mail: tim@bci-engineering.com

USA

Jerry Carroll, Director of Sales

" Phone: (724)-689-8532
" Fax: (724)-240-1500
" E-mail: jerry@bci-engineering.com