ENGINEERED PRECISION CASTING

Precision where it matters most.

With world-leading experts, rapid prototyping and delivery, and the most advanced investment casting facilities in the world, BRK Metal is redefining how today’s manufacturers create, refine, and deliver products.

What is precision casting?

The term “investment” may bring dollar signs before the eyes of those who are not familiar with the process. Actually, it refers to the ceramic materials that are used to build a hollow shell into which the molten metal is poured to make the castings. The origin of the term investment comes from the solid mold process where a plaster type material is poured or “invested” into a container that holds a clustered tree of small plastic patterns that are identical to the casting being produced. After the plaster has set, the disposable patterns are burned out leaving a hollow cavity into which the metal is poured.

The same holds true for the investment or “lost wax” casting process. Wax is injected into an aluminum die to produce a pattern that is an exact replica of the part to be produced. For every casting, a wax pattern must be manufactured. The patterns are clustered around a coated sprue and repeatedly dipped into an agitated vat of ceramic and allowed to dry. After a shell thickness of approximately 3/16″ has been built; the molds are dewaxed by either flash firing at high heat (1400 F.) or autoclaving (pressure and steam). The hollow shells are then preheated to 800-2000 F. depending on the alloy to be poured and the molten metal cast immediately into the hot shell. After cooling, the ceramic is vibrated and blasted off the metal parts and discarded. The balance of the cleaning operations (cut off, grind, heat treat, straightening, blast) are straight forward and quite similar to the other casting processes.

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Why to choose Precision Casting?

Machining Cost Reduction

Surface quality

Design Freedom

Cost Savings

Alloy Metal Diversity

Low and Long Life Mold Cost

Production in High Quantity in a Short Time

Phase 1: Mould engineering & production

Precision investment casting starts with the engineering & production of a casting mould, also known as a wax tool.  This mould is home-developed by BRK Metal engineers and serves as a ‘negative’ of the final casting. With use of a casting mould a wax model can be sprayed with a very accurate dimension and an excellent contour sharpness. These wax models are glued together onto a so-called wax ‘tree’ on which a casting funnel is mounted. In a later stage of the process, steel is poured into the funnel. Depending on the size of the series, the mould is installed either onto a manual or automatic press.

Phase 2: Ceramics

After the wax models are glued together, the tree is given a fireproof ceramic shell. This shell is constructed by repeatedly submerging the tree (up to 7 or 9 times) in a slurry and sprinkle it with ceramic sand. The ceramic layers are then hardened in a drying chamber, exposed to air.

After the layers have been formed and dried, the wax is melted out of the ceramic tree by using steam (120°C) in an autoclave. This is why it is called ‘lost wax casting’.  The molten wax can be regenerated and is reusable. The ceramic tree is then baked at a high temperature (1100°C) and reaches its final strength through the sintering process. Wax leftovers are burned up during this process.

Phase 3: Casting process

The desired steel alloy is melted in a large furnace and brought to casting temperature. The ceramic tree is, at the same time, heated in a oven to prevent thermal shocks during the casting process. After the tree has been heated, it is removed from the oven by a robotic arm and the steel is poured in by means of counter gravity. When the trees have been cast, they have to be cooled on a cooling conveyor (with nitrogen). The trees are then removed from their ceramic shells, by breaking the shell with a fully-automatic knock-off hammer. This removes most of the ceramic.

Phase  4: Finishing & Machining

The remainder of the ceramic is removed in the Finishing Department by means of steel, sand and/or water blasting. The next step involves sawing or vibrating the products off from the steel tree. The steel leftovers are sorted on alloy and may be melted again during the next casting badge. Finally, the ingate is sanded off, the product is machined, calibrated or heat-treated when necessary. After the final inspection, the products are ready for shipment to another satisfied BRK Metal customer.

Aluminum Precision Casting

Aluminum Precision Casting Technology

Aluminum is a material that can oxidize quickly and is difficult to cast. This substance, which is very difficult to process, is an important source of use for many sectors. Having a light-resistant structure, aluminum has an important place in many sectors thanks to its durability and longevity. Finding a place in many fields, especially in automotive, aluminum has a very important place in the global market.

Aluminum Precision Casting Process

Aluminum, a silver-colored metal with an atomic number of 13 in nature, with a melting temperature of 660 degrees, is an important metal used in many different sectors. Having properties such as low density, high rigidity, specific strength, shaping capability, long life, high toughness, corrosion resistance, conductivity, recycling, aluminum can be produced in the desired design and size thanks to the precision casting process. In the aluminum investment casting process, the aluminum melted at high temperatures is poured into the pre-modeled ceramic mold and allowed to cool. After the solidification process, the product is separated from the mold and final arrangements are made.

Aluminum Usage in Different Sectors

Aluminum, which plays a major role in reducing energy costs and carbon emissions, helps to reduce transportation costs and CO2 emissions thanks to its recyclable and light features. This substance, which is frequently used in areas such as aviation, space and defense industry today, ensures successful results in production. Aluminum, which is very advantageous in terms of both product design and production efficiency, is used in many sectors all over the world. 

Other Areas Where Aluminum Is Used 

It can be used in aluminum gearbox bodies and pistons, parts of small household appliances, kitchen hand tools, textile machinery and other machines. Specially designed with ceramic casting molds, these materials ensure perfect results when processed by experts. After preparing a separate mold for each product to be produced, the main parts are produced with the part to be produced, in exact dimensions. Thanks to modeling, it is also possible to take a sample of the part to be produced. This saves companies from unnecessary cost budgets by ensuring that each product is produced flawlessly in multiple orders. 

Expertise in Aluminum Precision Casting Process 

Ceramic casting molds should be specially designed while aluminum precision casting is carried out. Particular attention should be paid to deoxidation while performing the aluminum investment casting process in order to prevent the formation of gaps in the castings. Thanks to a special method we have developed within BRK Metal, we put our signature on products with minimum gas gap and maximum strength for each product we produce. Our company, which has the capacity to produce aluminum precision casting parts that can meet the quality standards of the aviation industry, effectively meets the aluminum precision casting needs of all sectors.

Magnesium Precision Casting

Magnesium Precision Casting Technology
 
Magnesium is an alloy that is lightweight and has high specific strength properties. This material, which has an important place in the transportation and defense industry, has low soil and strength values ​​without alloy. Therefore, it is necessary to alloy the product in areas where magnesium is used, such as AZ91, AZ63 and WE54. Having high thermal conductivity, magnesium also has good electromagnetic shielding, high dimensional stability, good workability, high damping and easy recycling. This material, which has advantageous features, is used in many areas from automotive to mobile phones, aviation to sports equipment. In recent years, magnesium, which has also found a place in efforts to use energy resources more efficiently in order to ensure sustainability, is also effective in reducing fuel consumption in the automotive sector.
 
Casting of Magnesium
 
Magnesium, which is also used to make vehicles lighter, has a special importance in the defense industry and automotive sector thanks to its lightness and high strength. The investment casting process is also used to shape this material, which is used in many sectors in the global market. In the investment casting process, the modeling of the product to be produced is made by wax molding method. The created modeling is covered with a heat resistant ceramic mold. Then the mold is expected to dry. After the mold is completely dry, the wax model in it is taken back with pressure, and then it is poured by melting method. In this way, magnesium, which is the main material of the product to be produced, is melted and poured and the product is left to cool. Magnesium, which has an extremely flammable and dangerous melting feature, should be poured with the help of special gases. After the process is completely cooled, the ceramic is separated from the mold and after the runner cutting process, the processes to be prepared for the customer begin.
 
Precision Casting Process in Mass Production Parts
 
Magnesium precision casting can also be used in mass production products. With the precision casting process that ensures the perfect creation of the most challenging parts, liquefied and melted metals are poured into a specific mold and transformed into new parts in the desired shape and form. In these processes, it is possible to produce the product desired to be formed millimetrically without any problems. This system, which enables the production of even the most demanding products with a complex design, is the lifeblood of the industry. Magnesium, which has an excellent mold filling feature, is preferred over other metals with this feature. Its low heat capacity and efficiency in the solidification process have also been effective in using this metal in production.

Bronze Precision Casting

Bronze Precision Casting Technology

Bronze material, which has been found in nature for centuries, meets the metal parts needs of many sectors today. Bronze, also known as bronze, is an important alloy of copper. Although bronze, which is a harder material than copper, was widely used in weapon and tool making, art works and ornaments in the first years, it is used in many sectors from automotive to electrical household appliances today.

Bronze Casting in Areas Requiring Precision Manufacturing

It is very difficult for copper alloys made of copper and tin or aluminum to take shape. In areas that require precision production or in alloys that are detailed in design, bronze precision casting is used to obtain products in desired dimensions. Bronze, which is also used in alloys such as copper-nickel, copper-beryllium and copper-zinc, comes in different varieties. Aluminum Bronze and Red Bronze are among the most well-known bronze types. Copper-based alloys containing up to 14% aluminum are called Aluminum Bronze. Al-Bronzes have high mechanical and chemical properties. Hardness degrees can go up to 42 – 45 HRC.

Bronze Precision Casting Process

Precision casting is a casting technique in which wax is used in the mold formation stage. In this technique, which uses a wax pattern in molding, the mold cavity is heated and melted when the wax leaves the mold. A method that has been used since ancient times continues to be used today. Not just bronze; We ensure the production of flawless alloys with these processes, which is a casting technique we use in shaping metals such as aluminum, iron and steel. With our systems that enable the products to be produced in millimeters, we ensure that even parts that cannot be produced from the smallest parts are created without any problems. In the systems we have created using the most sensitive techniques, we melt the bronze alloy and pour it into ceramic molds using wax, and thus we obtain a new bronze in the desired dimensions and dimensions.

Mold Stage of the Bronze Precision Casting Process

Wax is used in the molding stage of the bronze investment casting process. A sample model of the piece to be cast is extracted from the wax. After the wax model is covered with ceramic mortar, the ceramic shell formed is cast into the mold. As a result of this casting process, the liquid bronze solidifies and takes the shape of the mold with a hollow inside and thus the part. During this solidification, the metal is separated from the ceramic mold and the part is produced. This part is ready for use after cleaning and polishing.

Use of Bronze in Systems Using Sea Water

Bronze materials are preferred in systems using sea water. In addition, bronze is used in low conductivity environments. Mold, runner and feeder design is very important according to the types of bronze investment casting. Raw materials used for liquid metal, melting furnaces used and deoxidation are very important and important factors for this material. At BRK Metal, which performs the shaping process of bronze with the latest technological materials and a team of experts in the field, we are pushing the possibilities, superiorities and limits of production methods to create higher quality in engineering. By creating a theoretical and practical infrastructure to produce the best with our bronze precision casting processes, we increase the quality of the resulting products in parallel.

Alloy Selection

Investment casting provides ultimate design freedom, variety, and alloy selection. And at BRK Metal, we have more than 150 alloys to choose from. You can choose the best alloy for your project.

QUALITY COMES FIRST

DESTRUCTIVE INSPECTION

-Chemical Spectrometer Analysis

-Hardness Analysis (Brinell, Rockwell)

-Metallurgical Grain Structure Analysis

NON-DESTRUCTIVE INSPECTION (NDT)

-Radiographic X-Ray Analysis

-Liquid Penetrant Analysis

-3D and Optical Dimensional Analysis

-Solidification Modeling

About Us

With the investments it has made in the Precision Casting Industry since 2002, it offers the production of precision casting metal parts from 1 gram to 25 kilograms, from 1 millimeter to 400 millimeters, with the latest model machine infrastructure to its domestic and foreign customers. BRK Metal, which makes 60% of its production abroad, is the approved supplier of many well-known companies in Europe. Working customer-oriented with its young and talented staff, BRK Metal has proved that it is a reliable supplier with timely and trouble-free deliveries by producing at affordable costs to its customers without compromising its quality. With the ISO 9001: 2015 manufacturing principle, it has gained the satisfaction of many customers and has managed to attract more attention from companies that do not know and do not use the precision casting (wax casting) method with the technological infrastructure investments that change day by day.
 
 
Contact Us

+90 (216) 394 40 04