Conversion of Fabrications to Castings or Forgings

If you are considering the conversion of your fabrications to castings or forgings, CAB Incorporated provides the necessary services to help you make an informed decision. CAB’s strong foundry, forging and machining experience helps customers to convert fabricated assemblies to lower cost components. With their global footprint, they can use both local and overseas engineers to lower total costs even more.

CAB's engineers will begin the process with an analysis of your fabricated product's suitability for casting or forging. Once found suitable, CAB will then design the castings or forgings for manufacturing, review the entire process, and then generate the fixturing and tooling necessary. CAB's casting methods include high-integrity modern sand castings, quality pressure containing castings, and centrifugal castings. They can produce rough conditioned castings as well as pre-machined and finish machined castings. CAB casts and forges an impressive selection of materials, including numerous steels, irons, aluminum, and bronze weighing up to a maximum of 73,000 lbs. and measuring to heights up to 6'. In-process and post-production inspections are followed with final inspections using a coordinate measuring machine for the ultimate in accuracy. Castings and forgings are then subjected to a battery of tests - destructive, non-destructive, hardness, ultrasonic, X-ray, and metallurgical and failure analyses. Quality control parameters are set before the process begins and are then maintained throughout production. Documentation for all castings and forgings consist of dimensional inspection results, heat treatment charges, and the results of FMEA and PPAP testing. CAB has a full pattern shop and can also provide kitting, design fixturing, and gauging services.

ISO 9001 and 14000 certified, CAB brings the efficiencies of QMS, MRP/ERP Systems, and lean manufacturing to both short and long production runs, all certified by their Six Sigma Certification (Black Belt) staff members. CAD files from AutoCAD, SolidWorks, and Pro/E can be used to guide casting and forging operations, all of which are done to TS 16949, ASTM, ANSI, ASME Y14.5 standards.

If you are wondering if you should convert the production of your fabrications to castings or forgings, let the experts at CAB Incorporated give you the answer. Contact them today or see the following table for additional information.

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Conversion of Fabrications to Castings or Forgings Capabilities

General Capabilities Performed
Analysis of Fabricated Product Suitability
Design for Manufacturing (DFM)
Process Review
Fixturing and Tooling
Casting Methods Available
Investment Castings
Sand Castings
Permanent Mold Castings
Lost Foam Castings
Shell Mold Castings
Precision Machined Castings
Centrifugal Castings
Forging Methods Available
Open Die Forgings
Closed Die Forgings
Seamless Rolled Rings
Casting or Forging Features
Rough Condition
Pre Machined
Finish Machined
Materials We Work With
Low/Medium Alloy Cast Steels
High Strength / Hardened / Temperature Resistant Steels
Corrosion and Temperature Resistant Stainless Steels
Wear and Impact Resistant Steels and Iron
Grey, Ductile and Cast Iron
Aluminum
Stainless
Bronze
Casting Height
Varies - Recent experience up to 6 feet in height
Casting Width
Varies
Casting Length
Varies
Casting Weight
Up to 73,000 lbs.
Tolerance
Per ISO 8062 DCTG 4 to 12 depending on casting size & material
Inspection Services Performed
In Process
Post Production
Final
Fixtures and Gauging
Coordinate Measuring Machine (CMM)
Testing Services Performed
Destructive
Non Destructive
Hardness
UT
X-Ray
Mag Particle Inspection
Liquid Penetrant Inspection
Metallurgical Analysis
Failure Analysis
Quality Assurance
ISO culture with Six Sigma skills
ISO 9001 Certified Quality Management Systems
ISO/TS16949 Automotive QMS
ISO 14000 Certified EMS
5 Why Root Cause Analysis
8 Discipline (8D) Problem Solving
Error Proofing (Poka Yoke)
Statistical Process Control
MRP/ERP Systems
Complex Metrology per ASME Y14.5
Documentation
Material Test Reports
Dimensional Inspection Reports
Heat Treatment Charts
Packing & Shipping Documents
FMEA
PPAP
Control Plan
Additional Services
Full Pattern Shop
Kitting
Design Fixturing and Gauging
Production Volume
Short Run to Large Run Production

Additional Information

Industries Served
OEM Components
Automotive
Oil and Gas
Hydraulic
Railroad
Industrial
Mining
Construction
Agriculture
Waterworks
Wind
Solar
Intended Applications
Hydraulic and Actuator Components
Oil & Gas Components (shafts, pinions, valve bodies)
Automotive Engine Components (shafts, pinions, bushings, wheel hubs, cylinder blocks, intake manifolds, exhaust manifolds, starter spacers, pulleys, engine mounting brackets, water transfer connections)
Industrial OEM Castings and Forgings
Rail Track Accessories (clips, jaws, hook twin tie plates, crossing parts, track bolts)
Locomotive counterweights
Aggregate Crusher Wear Parts and Hammers
Waste Industry Components
Steel Pipe Flanges
Valve Bodies
Flowmeter Components
Equipment Components
Hydraulic Rod
Clevis
Actuator Components
Counterweights
Mining Counterweights, Hammers, Wear Parts and Augers
Rotary Kiln Rings
Industrial Machinery
Wind Tower Components
Pumps
Valves
Meters
Agriculture Equipment Components and Attachments (cultivator wear parts, track pads, other wear parts)
Industry Standards Met
ISO 9001
TS 16949
AWS D1.1
ASME Section IX
QMS
ISO 14000
ASTM
ANSI
ASME Y14.5
MRP/ERP Systems
Efficiency
Six Sigma Certification (Black Belt)
Lean Manufacturing
File Formats Accepted
AutoCAD
SolidWorks
Pro/E

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