should be a focal point of your site visit. First, the metalcaster must control the mold
media. For instance, sand casters must regulate moisture and binder levels to ensure consistent and predictable results. Sand casters should have a full time lab that performs daily batch testing on its molding and core sand. Tight controls in this area not only will provide better surface fi nish, but they also will help reduce casting defects, which improves on-time delivery percentages. Likewise, permanent mold shops and other plants should demonstrate an active preventive maintenance program for ensuring high quality mold materials. In order for a casting supplier to meet your
chemistry requirements, it will need a sound metal- lurgical department. A metallurgist, responsible for all chemical and mechanical testing of your product, will head this department. T e metallurgi- cal department should perform tests on each heat of metal poured and retain the results. T ese results will be used to certify the material you purchase and trace material poured in the past in the case of a problem. Once the chemical requirements of the molten
metal have been met, the responsibility of meeting your castings’ required mechanical properties falls on the heat treat facility. If the metalcaster per-
forms heat treating in-house, extra time should be spent by the audit group in this area, with a focus on furnace controls and quenching capabilities. While touring a potential metal casting sup-
plier, ensure that a sound quality system, including the use of control plans and detailed work instruc- tions, is in place. Ask to see the work instructions in each area of the facility. Metalcasting facilities traditionally have high employee turnover, so someone off the street may have to perform the work at some point. T e instructions should be written accordingly. Your new source also should have and utilize an active sampling and produc- tion part approval process. Make a review of these processes a priority. Experienced engineering departments can
ensure you receive sample submissions that meet your quality requirements the fi rst time. Typically, the metalcasting engineering department also manages the construction, maintenance and stor- age of all pattern equipment, which is an impor- tant asset, so you must understand how it will be stored and maintained.
Beyond Vetting As procurers of metal castings, you should
want to go beyond fi nding a competent metal
Your metalcaster must know the quality of its raw materials to produce components to your specifi cations. METAL CASTING DESIGN & PURCHASING / 2012-13 Metalcaster Prospectus 5
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