Alternative Methods to Die Casting :

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Discussion Overview

The discussion revolves around alternative methods for fabricating small tubular components from Copper-Beryllium or Copper-Nickel alloys, specifically for heat-transfer applications. The participant seeks high precision in low volume, expressing concerns about the cost-effectiveness of die-casting.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant inquires about methods to fabricate a custom-designed copper alloy part with precise dimensions, emphasizing the need for a maximum of 20 pieces to avoid high costs associated with die-casting.
  • Another suggests using a lathe and reaming, recommending consultation with a machinist for assistance, while also mentioning the possibility of brazing a hollow semisphere onto the pipe.
  • A participant mentions that machining from bar stock should not pose a problem if the material is available.
  • Lost wax casting is proposed as a potential method, noted for being inexpensive and sufficient for jewelry applications.
  • One participant references a company that has provided assistance with lost wax casting in the past, suggesting contacting them for help.
  • A participant shares their experience with rapid casting, indicating it can be effective for small parts and inquiring about the budget for the project.

Areas of Agreement / Disagreement

Participants present multiple competing views on fabrication methods, with no consensus reached regarding the best approach for the specific requirements outlined.

Contextual Notes

Participants express varying degrees of familiarity with the suggested methods, and there are assumptions about access to tools and materials that may not be universally applicable.

Who May Find This Useful

Individuals interested in metal fabrication techniques, particularly for small, precision components in low volumes, may find this discussion relevant.

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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