Vacuum Furnace Services
Waukesha Foundry is Home to the Largest Vacuum Melting Furnace in North America
Advanced Capabilities of Our Vacuum Furnace Services
Waukesha Foundry has always been committed to delivering precision-engineered parts, and our vacuum furnace services are an extension of this commitment. Our vacuum melting services allow us to cast nearly any alloy or superalloy into a precision part in a highly controlled environment. This reduces the chance for gas and slag inclusions, since there is minimal exposure to atmosphere at the high temperatures created in the furnace. Vacuum furnace casting also allows us to have greater quality control over the part’s chemical composition and mechanical properties. With the largest vacuum furnace in North America, we also deliver capabilities and benefits that set us apart:
Melting Capacity
Large or heavy parts are no challenge for Waukesha Foundry’s vacuum furnace. We can melt up to 4,000 pounds of material to tackle any large-scale application. Our extensive metallurgical experience and material options also allow us to meet even the most exacting customer requirements.
Powerful Kilowatt Output
Our highly efficient vacuum induction furnace makes quick work of even the hardest-to-melt metals and alloys. It can reach 1,000 kilowatts quickly and utilizes a magnetic field to transfer heat and melt materials at high speed – a critical need when trying to eliminate chemical oxidation.
High Temperature Range for Exotic Metals
Waukesha Foundry vacuum melting delivers seriously high temperatures for rapid melting that enhances the purity of the finished product. With the ability to achieve 3200ºF we can process exotic metals and refine any metal into a higher quality casting.
Argon Refining Options
Argon bubbling provides an added benefit against oxides and inclusions, offering an active removal of these potential defects rather than just shielding. The bubbling argon causes dissolved gases like nitrogen and oxygen, which can cause problems if not removed, to stick to the bubbling argon. These gases then float to the top of the molten bath and are removed by the vacuum pumps. This reaction is even more effective with the added magnetic stirring capabilities of our vacuum furnace. By reducing the need for degassing alloys near the end of the melt, we further limit the risk of added gas and inclusions.
Lower inclusion contents in the molten metal allow for:
- Increased and more consistent mechanical properties
- Pouring at lower temperatures, which increases part yield and decreases the risk for shrinkage defects
This process showcases the adaptability of our vacuum furnace services to different materials and enhances the overall quality and integrity of the finished product.
Why Choose Waukesha Foundry for Vacuum Furnace Services?
Waukesha Foundry has earned a reputation as an innovator in the production of intricately shaped cast components. Our commitment to our customers’ needs led us to invest in North America’s largest vacuum furnace equipment. It is one of many ways we help our customers meet their challenges: from complex geometries to razor-thin components, from rare materials to advanced metallurgical manipulation. Our vacuum furnace services allow us to not only handle and manipulate heat-resistant and difficult to process alloys, but our experience also assures we can obtain the highest levels of purity needed for critical components.
Quality Assurance
Our entire foundry is built around quality results and consistent output. No matter how complex the design or high tight the tolerances, quality control is built into every step of our vacuum induction furnace process. In addition to utilizing the latest diagnostic and manufacturing technologies, we invest in our people. We utilize Six Sigma principles throughout our operations, and our certified Black Belts assure we are meeting and exceeding our customers’ exacting standards. We hold many quality certifications including ISO 9001:2015 by TÜV Rheinland.
Industries Served
Purity and integrity are important in any industry. Our vacuum furnace’s advanced high-heat capabilities and high capacity make it ideal for delivering a variety of essential and custom parts for the aerospace and defense industries. From large-scale mechanical components to precision-engineered fasteners, our vacuum furnace can help us build parts that stand up to the toughest challenges planes and military equipment face.
We’ve also developed custom parts for the automotive, energy and power, and general manufacturing sectors. Our ability to manipulate materials at a large scale allows us to produce almost anything our customers can dream up.
FAQs
How does the vacuum furnace benefit the aerospace industry?
Waukesha Foundry’s vacuum induction melt system offers state-of-the-art control that is critical to the parts used throughout aerospace design and engineering. Our vacuum furnace allows for precision control over critical alloys – keeping them free from pollution and oxidation.
What types of materials can be processed in the vacuum furnace?
Waukesha Foundry vacuum furnace services are ideal for alloys that are difficult to process or require a high level of purity. Our vacuum furnace can reach temperatures as high as 3200ºF, allowing us to melt and manipulate a variety of metal alloys and superalloys, including Inconel, and 300-level steel alloys. For example, we can decarburize 316 and 304 stainless alloys to make 316L and 304L.
Can the furnace handle large-scale production?
Our melting capacity is the largest in North America. We can melt up to 4,000 pounds of material to tackle any large-scale application. When a high volume of parts is needed, we can work with you to develop a timeline that keeps your production moving forward.
Is Waukesha Foundry certified for quality assurance?
Yes. Waukesha Foundry is ISO 9001:2015 by TÜV Rheinland certified. In addition, we utilize Six Sigma principles and employ several certified Black Belts throughout our operations.
What is the vacuum level of a vacuum furnace?
The Waukesha Foundry vacuum furnace can achieve vacuum levels as low as 10m bar.
What types of heating elements are used in a vacuum furnace?
The Waukesha Foundry doesn’t utilize traditional heat treatment elements. It is an induction melting furnace. A copper, water cooled, coil surrounds the conductive material to be melted. The coil induces an electric current in the melt material by a changing magnetic field, resistive heating causes the material to begin to melt.
See what we can do for you.
Customer satisfaction is important to us. We work closely with our customers to engineer the right process for their application. To find out what Waukesha Foundry can do for you, contact us today.