Pennsylvania Precision Cast Parts, Inc. has produced 70/30 copper-nickel investment castings since the company was founded in 1983. That experience has been earned one pour, one casting and one production challenge at a time. Today, PPCP supplies castings to companies that require dependable material performance and closely controlled manufacturing.
Why is Copper-Nickel 70/30 Difficult to Cast?
The qualities that make copper-nickel 70/30 valuable also make it challenging to process. It is not an alloy a foundry masters through a small number of experimental pours.
Four technical factors make experience especially important.
1. Alloy chemistry must be tightly controlled
The copper-to-nickel ratio and specified trace elements must remain within narrow limits. Chemistry that moves outside the required range can affect the corrosion resistance and material properties for which the alloy was selected.
2. The alloy requires elevated pouring temperatures
The nickel content raises the melting range beyond that of many common copper alloys. Higher processing temperatures increase demands on melting practices, pouring control, shell performance and foundry personnel.
The ceramic shell must withstand the thermal conditions while maintaining the geometry and surface characteristics required by the part.
3. Molten copper-nickel is sensitive to gas absorption
The melt can absorb gases if it is not handled correctly. Improper melt practices can result in porosity that may not be apparent from the casting’s exterior.
Controlling the melting and pouring process is therefore essential to producing sound castings. Decades of experience help a foundry recognize how variations in temperature, time, handling and geometry can influence the finished component.
4. Investment casting adds another technical layer
Investment casting uses a ceramic shell rather than a conventional sand mold. The process can produce complex shapes, fine details and near-net-shape components, but it requires close coordination among pattern production, gating, shell building, burnout, melting, pouring and finishing.
PPCP combines its experience with copper-nickel 70/30 with investment casting capabilities that include ceramic and soluble wax cores, semi-automatic injection, robotic systems and automated grinding. PPCP produces specialized-alloy investment castings in sizes up to 250 pounds. (PPCP Inc.)
Applications for Copper-Nickel 70/30 Investment Castings
Investment-cast copper-nickel 70/30 components may be considered for systems requiring a combination of corrosion resistance, erosion resistance, durability and complex geometry.
Potential component categories should always be evaluated against the applicable drawing and procurement specification. They may include parts associated with:
- Seawater-handling systems
- Pumps and pumping equipment
- Valves and flow-control equipment
- Marine process equipment
- Shipboard piping systems
- Heat-exchange systems
- Fluid-handling components
- Complex corrosion-resistant hardware
PPCP’s website identifies valves, pumping equipment, process equipment, controls and compressors among the industries and applications served by its investment casting operation. (PPCP Inc.)
A Proven Source for Challenging 70/30 Copper-Nickel Castings
70/30 copper-nickel is selected for applications where corrosion resistance and dependable material performance are essential. Producing a sound investment casting in Cu-Ni, however, requires far more than access to the correct raw material.
It requires control of chemistry, temperature, gas, shrinkage, shell performance, gating and testing. Most importantly, it requires experience.
PPCP has been casting this specialized alloy since 1983. For manufacturers seeking 70/30 copper-nickel investment castings PPCP offers an established combination of alloy knowledge, investment casting capacity and stringent quality control.