Alternative Methods to Die Casting :

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SUMMARY

The discussion focuses on alternative fabrication methods for creating small tubular components from Copper-Beryllium or Copper-Nickel alloys, specifically with dimensions of R1 = 5mm, R2 = 6.5mm, L = 40mm, and Rc = 3mm. Die casting is deemed too expensive for the required quantity of 20 pieces, prompting suggestions for more cost-effective methods. Recommendations include using a lathe and reaming, consulting a machine shop, and considering lost wax casting or rapid casting techniques for precision and budget-friendly solutions.

PREREQUISITES
  • Understanding of machining processes such as lathe work and reaming
  • Familiarity with casting techniques, specifically lost wax casting
  • Knowledge of brazing methods for metal joining
  • Basic principles of heat transfer applications in metal components
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  • Research lost wax casting techniques for small precision parts
  • Explore rapid casting services for low-volume production
  • Learn about machining processes specific to Copper alloys
  • Investigate the properties and applications of Copper-Beryllium and Copper-Nickel alloys
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Engineers, machinists, and product designers involved in the fabrication of precision metal components, particularly those working with Copper alloys for heat transfer applications.

ronvieky
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Anyone knows of any alternative methods ot fabricate a Copper-Berrilium / or Copper-Nickel / alloy into a small tubular form (Custom design)...

I need to Mold a Copper Alloy with the following dimensions : Precision required.


http://www.fileden.com/files/2008/4/23/1880222/Copper%20Tube%20Fabrication.JPG

R1 = 5mm
R2 = 6.5mm
L = 40mm
Rc = 3mm

(tip of this part is conical, and Closed, hence radius of this Hemisphere end Rc )

And that's it. But i need a maximum of 20 Pieces of this part. So i cannot go for Die-casting. It'l be way too expensive for me... Does anyone know of any other methods to fabricate this in Copper - or any of its alloys?

I need it for Heat-transfer applications, which may involve rapid heating and cooling of the part. What is the best way to do this? and the cheapest. cuz, i don't want high volume. only high precision.

Please suggest.

Thanks.
 
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I was going to suggest a lathe, and reaming, but that's after mistaking your dimensions as cm. If you have access to a machine shop / good machinist you should probably talk to them and see if they might be able to help you. On the other hand, you'd probably be able to braze a hollow semisphere onto the pipe, but that might impact your intended use:
http://en.wikipedia.org/wiki/Brazing
 
If you can get it in bar stock you shouldn't have a problem machining it.
 
lost wax casting ?
cheap
good enuff for jewelry
 
Not sure but in the past, these guys have given us detailed help with lost wax / http://www.deangroup-int.co.uk/" queries. May be try giving them a call?
 
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i have used rapid casting in the past and that is good for up to 50 off depending upon the tool. Quite a small part so shouldn't be too pricey. what's your budget?
 

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