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Foreign Component Inclusions

With the goal of increasing mold design flexibility in mind, PIAD can insert metallic components into our molds to broaden our application range. Qualifying inclusions have proven to be impactful for saving customers significant tooling costs.

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Foreign Component Requirements

The component needs to be of metallic nature with a melting point which exceeds the melting point of the PIAD alloy.

The surface of the metallic component must be clean of all organic substances.

Plating of the foreign component is possible as long as the vapor temperature of the plating material exceeds the pouring temperature of the cast alloy. Therefore, chrome and nickel plated parts can be used without problems, but zinc and cadmium plating are not acceptable.

What Can Foreign Components Do for You?

Security Against Rotation and Shifting

The foreign component is positioned in the precision-machined mold so it closes completely without flashing. To prevent movement during casting, features like grooves, flats, undercuts, splines, or knuckles are added to the component. Close collaboration between the PIAD casting expert and the design engineer ensures the best technical and cost‑effective results.

Gears: Special Cases

Spur and worm gears can be produced cost‑effectively with composite casting by using tin or aluminum bronze only on the teeth, where their properties are needed. The gear’s hub is instead made from a cheaper gray or ductile iron casting that is pre‑machined, preheated, and fitted into the precision chill mold. Its exterior is serrated and cleaned to ensure a strong mechanical bond with the bronze.

Parameters of Cast-In Technology

The choice to use foreign components in a casting design is mainly driven by cost and can add significant value. Items such as bolts, threaded inserts, pins, cooling tubes, heating elements, and bushings can all be cast into a PIAD chill casting. When doing so, enough casting material must surround the insert to ensure full coverage and a strong bond, with required thickness depending on the load the insert will face. For heat‑treated components like hardened bolts, care must be taken to prevent excessive temperatures that could anneal and weaken them.

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Talk with our professionals to learn how PIAD can provide you with foreign component inclusions permanent mold casting solutions.