Feed tube impellers for the Canica 2000 rotor. Chromium held inside 2%, hardness at 53 HRC in the as-cast condition, hole pattern on the 22 in PCD machined to print. We quote a casting plus machining route from your drawing.
Most of these show up at first article or at the first teardown, not at the drawing stage.
Heat-to-heat variation in chromium content changes abrasion resistance across a batch. When one impeller wears faster than the next, the rotor balance shifts and the feed tube starts rubbing. The spec only works if every heat is verified before pouring.
Pushing as-cast hardness to 53 HRC without a controlled cooling cycle leaves internal stress. Parts pass hardness checks and fail in service, usually at a section change or a bolt boss. Cooling curves must be written per section thickness, not per alloy.
Shrinkage allowance is often set from a table instead of measured. The 22 in pitch circle then comes in small, bolts will not drop through, and the whole casting is scrap. Pattern correction has to happen before the first production run, not after.
Prototype paint gets imported and production paint gets substituted. Color and film thickness drift, and the customer rejects the lot at incoming inspection. The coating callout needs a qualified equivalent locked in before pilot parts ship.
Casting, heat treatment, machining and coating handled under one quality system.
Every heat is sampled and read on a spectrometer before the pour. Chromium, carbon and manganese are corrected in the ladle, not after the fact. The 2% window is treated as a process limit, so the reading has to land near the middle of it rather than at the edge.
We keep the chemistry record tied to the casting serial, so a wear complaint can be traced back to the heat that produced it.
Hardness at 53 HRC in the as-cast condition is where most suppliers lose parts. The cooling cycle has to follow the section thickness of the impeller, and thick bosses need a slower path than the thin vanes around them. We write the curve per part, run thermocouples on the first pieces, and check hardness at three locations.
If a casting comes out soft, it is reworked to the same curve rather than shipped with a note.
Pick the route by quantity and how much of the pattern work is already done.
| Route | Best for | What we control | Tooling |
|---|---|---|---|
| Prototype casting | 1 to 5 pieces, design check | Chemistry, hardness, machined fits | Soft tooling |
| Pilot lot | PPAP submission, 20 to 50 pieces | Chemistry, hardness, 22 in PCD | Production pattern |
| Production run | 100 pieces and up, repeat orders | Chemistry, hardness, coating | Production pattern |
| Recast from your pattern | Existing tooling, worn out part | Chemistry, hardness, machining | Customer supplied |
The impeller is the entry point. Most programs need two or three of these.
Iron and alloy castings with controlled chemistry, from prototype tooling to production patterns.
Hole patterns, bores and faces cut in one setup on 16 simultaneous 5-axis centers.
Hub bores and mounting faces turned and milled to ±0.005 mm where the print calls for it.
Coating, black oxide and blasting matched to the coating callout on your drawing.
Pattern and fixture work for the first article before production tooling is cut.
Low-volume duplicates for fit checks when a full pattern is not justified yet.
| Item | Capability | Notes |
|---|---|---|
| Chromium control | Within 2% | Spectrometer reading per heat |
| As-cast hardness | 53 HRC target | Verified at three locations |
| Hole pattern | 22 in PCD | Machined after shrinkage check |
| Machining tolerance | ±0.005 mm | On critical bores and faces |
| Surface finish | Ra 0.8–1.6 μm | On machined sealing faces |
| Maximum part size | 4,000 mm | Larger parts quoted case by case |
| Coating | Qualified equivalent | Locked before pilot shipment |
| Documentation | PPAP on request | Chemistry and hardness reports |
Numbers we can stand behind, not claims.
Fifteen years of wear-part work, with chemistry and heat treat handled in house.
Spectrometer reading per heat, corrected in the ladle before the pour.
Cooling curve written per section thickness to avoid cracks at the bosses.
Shrinkage measured on the first pieces, then the pattern is corrected.
Drawing review and quotation returned within 12 hours.
Parts ship in 3 to 5 days once the castings are released.
Impact rotors and feed tubes. The industry requires chromium control and hardness that survives rock and concrete feed.
Cast then machined housings and wear plates. The requirement is a repeatable pattern and a documented heat record.
Single replacement impellers and small rebuild lots. No minimum order quantity, so one worn part can be recast.
Yes, and we treat 2% as a window rather than a ceiling. Each heat is sampled and read on a spectrometer before the pour, and additions are made in the ladle while the iron is still liquid.
The reading is recorded against the casting serial. If you need the chemistry report with the shipment, ask for it on the purchase order.
Hardness and cracking pull in opposite directions on a part with thick bosses and thin vanes. A single cooling recipe that hits 53 HRC on the vane will usually crack the boss.
We write the cooling curve per section thickness and run thermocouples on the first pieces, then check hardness at three locations.
Shrinkage is measured on the first castings instead of taken from a table, and the pattern is corrected before the production run starts.
The 22 in PCD is then machined after casting, so the finished pattern lands on the print rather than near it.
Yes. If your pattern is still serviceable, we pour from it and handle heat treatment and machining in house.
Send the pattern drawing and a worn sample if you have one. We check the wear areas before quoting so the recast addresses the failure, not just the shape.
We qualify an equivalent coating before pilot parts ship, and the same coating goes on production. Color and film thickness are checked against the approved sample.
If your drawing names a specific product, tell us at quoting stage so the equivalent is approved before the first lot, not after.
PPAP is available on request. For pilot lots we submit chemistry, hardness and dimensional reports together with the parts.
Tell us which elements of the PPAP you need at quoting stage. Building the submission after the parts ship usually costs a week.
There is no minimum order quantity. We run from one prototype to 10,000+ part runs, with the same route either way.
A single replacement impeller is usually cheaper than a shutdown, so that is a normal order for us.
Quotation and DFM analysis come back within 12 hours of receiving a drawing. Production can start within 24 hours once the route is agreed.
Machined parts ship in 3 to 5 days after the castings are released. The casting lead time itself depends on pattern status, so send the drawing first.
Upload the feed tube drawing or a worn sample photo. We review the chemistry, hardness and 22 in PCD callouts and quote a casting plus machining route within 12 hours.
12-hour quote100% inspectionNo minimum order quantityNDA on request
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
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