Casting
We specialize in Metal Casting and provide a diverse array of casting processes and materials to meet the unique needs of our clients.
Our range of metal casting processes includes Investment Casting, Hard Sand Casting, Shell Mould Casting and Aluminium Die Casting.
Investment Casting
Investment casting, also known as lost wax casting, is regarded as a precision casting process to fabricate near-net-shaped components requiring complex shapes, often thin-wall, products that may not require future machining with accuracy, repeatability, versatility, and integrity in a variety of metals and high-performance alloys. Investment castings offer complex internal geometries, significant weight reduction opportunities, and unlimited alloy choices for the ultimate design flexibility.
The advantages of the investment casting process include:
Design Flexibility
Excellent surface finish
High dimensional accuracy
Complex, detailed, and intricate parts can be cast.
Freedom of material selection for casting
No flash or parting lines
Cost Effective
Production Consistency & Reproducibility
Wide Range of Application
HARD SAND CASTING
HARD SAND CASTING
Hard Sand Moulding uses refractory sand “hard bonded into place” as the mould material. This allows the sand grains to essentially be locked into place as they are moulded around a pattern of the shape that you want. The resultant hardened sand mould is what the molten metal is then poured into. The hard sand process offers.
. Enhanced quality of Green Sand processes
. High level of accuracy and consistency
. Jobbing or low volume production – the ability to produce from 1 to 1000 units per run.
. Complex shapes – undercuts and hollow centers can be formed.
. Capable of producing very large pieces.
SHELL MOULD CASTING
Also known as shell moulding offers.
- High dimensional accuracy
- Good surface finish
- High production rate
- suited to high production runs.
Typical parts are small-to-medium in size and require high accuracies, such as gear housings, cylinder heads, and crankshafts.
ALUMINIUM DIE CASTING
Merit specializes in the supply high pressure aluminium die castings.
Materials
We focus on aluminium alloys which include.
• ADC-12
• LM-2
• LM-6
• LM-24
• LM-30
• AlSi9Cu3,
• AlSi12
We use certified ingot and OES capability (Optical emission spectrometer) to analyze the chemical composition of every melt in production.
