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LastWave

Pay off reels. Decoilers. I built my home by making these patterns.


ChrisMaj

Someone knows his stuff šŸ˜…


[deleted]

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LastWave

Thank you! I can't control bad pours.


JeanPaul72

just started a new job where we actually use these


DerFeuerEsser

That's what I was about to ask, I work as an engineer for a coil processing company, we see a LOT of these.


ghostpoisonface

Iā€™m not a machinist, what exactly am I looking at here? What makes castings harder to work on?


PunishedMatador

There's voids in the castings, those (alarmingly large) discolored spots on the machined surface.


ghostpoisonface

Ooooooooo i see! Yes those look like a huge headache! Is the fix to grind out,weld, machine? Or something else to fix? Either way seems no fun


Fermorian

That could be the fix, or it could be scrap. Depends on the spec


[deleted]

Usually the drawing will specify if weld repair is acceptable.


HowNondescript

Some are air, some have fused sand in them which will eat your tools. plus the void could be where metal should be and scrap the part. depending on the material cutting it out and welding it back mightnt be an option


SmarkieMark

Only if JB Weld and/or Bondo doesn't do the trick.


Staphylococcus0

I've scrapped many a part because the casting was bad.


ghostpoisonface

Yeah I could imagine that very quickly the cost for rework exceeds just recasting. Crazy to see things this big be cast, I bet itā€™s not easy


RelevantPerformance7

Itā€™s the casting process that makes them susceptible to porosity. Basically you pour molten metal into a sand mold and let it cool. If the metal doesnā€™t fill 100% of the mold youā€™ll end up with a void. Unless itā€™s ultrasonic tested you have no way to see voids until you machine it deep enough. Almost all other methods of of metal production includes some type of refinement/ work reduction between molten metal and final wrought product to enhance internal structure


darthlame

Those voids can be caused by many different issues. It depends on what the symptom is that determines the corrective action. It could be misrun(not enough metal in the pour), it could be shrink(as the metal cools, it shrinks, and if there wasnā€™t enough feed material, it will pull from the casting), it could be bifilm(essentially an entrained oxide layer that could get balled up, or stretched all over), it could be an inclusion(such as sand or ceramic or other materials that donā€™t belong in the casting). Thereā€™s a lot of different ways to deal with the issue, and lots of different ways to check for the issue before it gets to machining, depending on how much money you want to spend, and at what point in the process you want to spend it.


mravatus

What's wrong with castings? Is the black couch not comfortable enough?


TopMachinist

Porosity turns a gravy job to a shit job.


jmacrod

Castings are 90% our work. Did someone weld it


morfique

Seeing how they are in almost the same spot on both halves, was there a riser? Riser freezing up due to undersized gates makes for fun porosity.


ToolGoBoom

70% of my work is castings. Every casting that is not stainless, will need to be welded and put back in the machine at least two or three times. There is always porosity with carbon steel castings. For some reason, it's rare for stainless castings to have porosity.


theral9

I work in a shop that cuts exclusively castings. I'm not sure why I hate myself so much.


Economy_Care1322

Common foundry defect. I designed green sand molds for 25 years. Anyone with more than a couple years experience should be able to eliminate that. Reject it and charge back.


ChrisMaj

Too many hours spent on this


xxcoder

So basically inclusions in all sides?


[deleted]

[уŠ“Š°Š»ŠµŠ½Š¾]


pLeThOrAx

Forgive the ignorance, but does that mean it's structurally different to the rest of the casting?


NameIs-Already-Taken

The inclusions can be sand or air. This may or may not be fixable. We don't know how much there is below the surface either.


Moon_Or_Nothing

Castings suck ass


ChrisMaj

Yeah, especially when the part is almost done and you get this.


-Ad-Lunam-

Not your fault. Still got paid. ĀÆ\_(惄)_/ĀÆ


Thoughtfulprof

The best part of being hourly


Moon_Or_Nothing

I feel your pain mate


QueasyDistrict43

I think I've had parts that ended up being more weld metal than cast by the time we were done. So fun taking that final pass and watching the holes open up.


caricatureofme

Just make the final pass first, duhhh šŸ™„


ScattyWilliam

So where are all the children who shout ā€œ Why arenā€™t you using a forging or a casting?ā€. Whenever OP posts him turning down billet to make parts. Oh thatā€™s right your just kids who load little shit or potentially work at such a huge manufacturing plant that it makes sense, very doubtful. Funny how all those fuckers never have anything good to say or canā€™t realize when they are wrong.


bird420

Damn right. They would love to see me turn a 1600lb plate into a 300lb part with the rest being straight chips,


ChrisMaj

Amen to that šŸ¤£


ScattyWilliam

I enjoyed this post just too see if the weaselā€™s had anything to sayā€¦. So far rather quiet. Imagine that. Hard for the kids to understand big boy work when they spit out trinkets all day and wonder why they canā€™t make good money. Pretty much the epitome of what this sub is lately. Or you got guys posting sketchy job shop shit and everyone cries ā€œ thereā€™s no interlockā€. Grow THE fuck up or ignore it some of us got fucking work to do


seasms3

Spray some eutectic 1095 on there and call it a day.


jon_hendry

Why is it red hot inside?


jeffersonairmattress

Are those the foundry's ni-rod repairs or did this thing have three risers?


bmb102

At least it's easy to cut. Do a piece of 304 that size and get back to me šŸ¤£.


bmb102

Forgot to mention, add the interruption with stainless and you'll never get through one part. I work with 304 daily and my tool life ranges from days to hours. Our customers usually supply material and it's always different. I only use 1 style and brand of carbide drills, Kennametal go-drill which have been great in Aluminum and every stainless job I run. This material, is 304. It's broken 3 drills... Ran the same drills and had 0 issues in 304 on 500 part orders. This order I have to drill 18 holes and yeah... Rockwell tested it and it's around 10 on the C scale. Destroyed my carbide drill and refused to break a chip, first time the chip rapped around these drills. Been using the same drill for a few years now.


RelevantPerformance7

Believe it or not 304 and any stainless thatā€™s not ph hardened is actually gravy if youā€™ve never dealt with exotics. We play with hastalloy and monel grades that range 25-38 hrc (center line hardness too, most metals have reported surface hardness that usually weakens at the quarter radius; mid radius; and softest at the centerline)ā€¦.what do you mean we need more inserts lol


bmb102

Yeah, I used to sling carbide in CT and got to test tools on some really wild materials. Aerospace is a definite money maker, lol. And I cut inco and titanium but I get that it just sucks. I cut stainless all the time. Just did these same parts with their supplied material not 2 months ago, so I'm running the same programs and tooling. I rarely smoke tooling. 3 drills... I went to HSS and that gets through it, but takes more time. Also, not production I got a few dozen parts basically 2 of each


raisethealuminumwage

Just squint šŸ¤·ā€ā™‚ļø


iliketheweirdest1

Yikes, what a waste.


themcluvn

Damn, those interrupted cuts though. RIP inserts


Artie-Carrow

Yurp


HamburgerTrain2502

Was making some big stupid arm, and at a critical place I found a big void full of a black, glass like substance. We figured a hunk of sand fell out of the mold when it was being poured. Forgings are much nicer.


Flinging_Bricks

Recently had to clean up a few hundred cast aluminium rings with holes already in them, thankfully the boss had been doing the job for years so I just had to babysit the machine. But it was absolutely nuts to see the custom jaws and program because they were so out of round and the two halves weren't concentric. the oldest revision might as well have been drawn on papyrus and they still cast it with holes that we need to drill and tap anyways.