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Similar
to the plastic injection industry, we are able to cast inserts
of all shapes, sizes, and materials into our permanent mold
aluminum castings. This technology is most commonly used to
remedy two situations. One situation is providing brass threads
instead of aluminum for more durability. The other is benefiting
from the weight savings of aluminum without compromising strength
where you need it.
Also,
if your tapped holes are currently having heli-coils inserted,
then additional savings can be realized by using steel or
stainless steel inserts, thereby eliminating the need to
heli-coil!
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| Components
of other materials can be integrally cast as part of the aluminum
casting with relative ease. In the photo to the right, a stainless
steel stamping is integrally cast into the Speed Sensor Bearing
Cap casting (shown above the golf ball). The advantage is an
extra-hard steel surface where needed, but light weight aluminum
everywhere else. The Front End Cap casting (shown beside the
golf ball) is cast with four threaded brass bushings in place
eliminating the need to drill & tap. The advantage in this case
is no machining coupled with the fact that brass threads are
more durable than aluminum threads. In high volume situations,
molded threaded inserts can actually be more economical
than drilling/tapping. |
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| The
critical feature of our insert design is a coarse knurl around
the OD (Fig. 1). This coarse knurl is what enables the insert
to lock into place. In essence, the molten aluminum flows
into every nook and cranny around the insert and then freezes,
thereby permanently locking the insert into position (Fig.
2). To "jack" the insert out of the casting would
require no less than shearing the aluminum all around the
insert. In other words, the casting would literally have to
break for the insert to fall out! |
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Figure 1
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Figure 2
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| In addition
to threaded inserts, we are capable of casting inserts of
just about any size, shape, or complexity. For example, a
high stress area can be reinforced with a steel insert while
the rest of the part remains lightweight aluminum. This technique
minimizes the overall part's weight while maximizing strength
and/or impact resistance where needed most. The application
of molded inserts in aluminum castings is virtually endless
and is limited only by the design engineer's imagination.
In summary, molded inserts can be both a powerful engineering
advantage as well as a potent cost benefit. We invite you
to challenge us with your ideas. |
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