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Hycast has the technology, Intellectual Property and experience to design products to meet high end specifications. For example, on an project such as the Dubai Terminal 3, Hycast completed the following design steps to ensure the product met the the load and design constrains;

  • 3D Computer Modelling: The first step of the design process is to develop a 3D computer model of the proposed casting and its components.

  • Finite Element Analysis (FEA): The FEA is a linear static finite element analysis of the casting to demonstrate the maximum developed stress when design loads are applied. 

  • Casting Simulation: Technology is used to simulate and visualise the entire casting process. This allows the team to establish the most effective and timely process minimising defects and maximising throughput.

  • Rapid Prototyping: Rapid Prototyping technology combines computer modelling with automated wax printing to produce a "near perfect" single casting. This technology is important as it allows the client to confirm shape, form and finish prior to the commencement of tooling.

A Successful Formula

Hycast Metals is in a constant frame of mind of "continual improvement" and has obtained the relevant accreditations to achieve that goal.

 

Hycast Metals accredited to:

 

World Class Manufacturing

&

Quality

  • Wax Injection: Wax replicas of the desired castings are produced by injecting tooling with wax. These replicas are called wax patterns.

  • Assembly: The wax patterns are attached to a central wax runner bar, to form an investment tree.

  • Shell Building: The shell is built by immersing the tree in a liquid ceramic slurry and then coating in a refractory product. Up to 5 layers may be applied in this manner. This stage is the creation of the “Investment mould”.

  • De-Wax: Once the ceramic shell is dry, the wax is melted out, using an autoclave creating a negative impression of the assembly within the shell.

  • Casting: The investment mould trees are fired in an oven and pulled out while hot. The shell is then filled with molten metal by gravity pouring. After the mould has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting. Cooling time depends on the thickness of the part, thickness of the mould, and the material used.

  • Knock Off: When the metal has cooled and solidified, the ceramic shell is broken off.

  • Cut Off: The parts are then cut away from the central runner bar using a high speed cut-off saw or band saw.

  • Finishing: Finishing operations such as grinding or sandblasting are used to smooth the part at the gates. Heat treatment may be specified to add further treatment to the final part.

  • Inspection: All parts are inspected for quality and shipped to the customer.

Product design

Process

the many shapes of success

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Lost was process

Alloys

Alloys can be chosen from a range of steels and stainless steels as well as nickel alloys, cobalt alloys, cast iron, brass, bronze, aluminium and other alloys to suit most purposes. Your own special alloys may be also made up for specific applications and certified in our NATA registered metals analysis laboratory.

The most commonly cast alloy groups are listed below;

  • 200 Series Stainless Steels - Ferritic

  • 300 Series Stainless Steels - Austenitic

  • 400 Series Stainless Steels - Martensitic

  • Precipitation Hardening Stainless Steels

  • Duplex Stainless Steels

  • Heat Resistant Stainless Steels

  • Abrasion Resistant Steels

  • Nickel Alloys

  • Carbon and Low Alloy Steels

  • Tool Steels

  • Cast Irons

  • Copper Alloys

  • Cobalt Alloys

  • Aluminium Alloys

Alloy Brochure : Tables listing the most popular alloys and their mechanical properties.

Hycast is a lot more than "just another investment casting company". The company offers the full range of technical skills necessary to ensure castings are managed effectively from design through utilization.

 

Hycast has manufactured engineered castings for the full spectrum of castings.

 

Hycast has completed prestige architectural projects across the world, including Dubai International Airport Terminal 3's distinctive tear drop windows and Hong Kong's One Island East foyer support structure, including 220 kg distinctive and unique vierendeel truss elements.

Manufacture of Unique Facade Brick

Central Police Station (CPS) Hong Kong

Hycast Metals has successfully engaged with high profile architects, engineers, contractors and projects in Hong Kong since 1998. Consequently, Hycast was invited to submit a proposal for the manufacture and supply of 8,200 aluminium bricks to be incorporated in the Central Police Station restoration project, Hong Kong. Hycast was asked to make this submission, as the architect was not satisfied with current offerings from 70 worldwide suppliers.

Hycast Metals as a company  has a strong structural engineering and metallurgical base, as a foundation. Hycast offered a low pressure die cast casting, incorporating the granite texture with a unique finish for aluminium. This is what the architect was seeking. Hycast won the contract on quality.

Precision Investment Castings

Hycast Metals