METAL CASTING & METAL WORKING

Non-Ferrous Metals For Industrial Applications

ACC Knows Metal Casting Advanced Materials

Non-ferrous metal casting (which is the process by which BADGERCOAST Galvanic Anodes, BADGERCONNECT Magnesium Anodes, and most BADGERCUSTOM are produced) and metal working are critical processes in industrial applications, producing metal products with specific physical and chemical properties. Industries, such as construction, transportation, and electronics, use non-ferrous metals, in their products. American Carbon specializes in BADGERADVANCED Titanium and BADGERADVANCED Magnesium alloys.

Superior Parts, Multiple Industries

Metal working shapes, bends, and cuts metal to produce a finished product, and it covers more ground than casting alone: forging, rolling, stamping, wire drawing, and tube forming are all standard parts of the toolkit. Extrusion sits apart from the others in what it does to the material itself, not just its shape.

Through heat and the extrusion process, the grain structure of the metal becomes more homogenous, producing a stronger, more consistent finished part than the same alloy would yield through casting alone.

Combined with machining, American Carbon extrudes parts across a wide range of industries and applications: structural framing, custom fittings, electrical bus bars and conductive hardware, heat sinks and thermal components, marine hardware, and transportation parts where weight matters as much as strength. Alloy selection comes down to what the part needs to do. BADGERADVANCED Titanium and BADGERADVANCED Magnesium make sense where weight and corrosion resistance outweigh raw material cost, while aluminum, copper, and other non-ferrous alloys cover the rest of the range.

Reach out to American Carbon to talk through your next extrusion project.

Improved Casting Efficiency

Non-ferrous metal casting covers many different processes depending on the required tolerances, price point, and volume of a casting, and matching the process to the part is most of the job. Whether the project demands gravity feed sand casting, metal mold casting, or high-pressure die casting, American Carbon selects the best process for the project demands from low-volume flexibility, better repeatability, or tight tolerances at higher volume.

A capability American Carbon focuses on beyond standard casting is embedding objects directly into castings during the pour, such as steel connection points or wear surfaces, which skips a secondary manufacturing step that would otherwise add cost and a potential failure point. Non-ferrous metals are lighter and more corrosion-resistant than ferrous, iron-based, metals, which is why they tend to win on part efficiency once weight and service life are factored in.

BADGERADVANCED Graphite is the standard mold, crucible, and tray material for most non-ferrous metal castings. Its thermal stability and low reactivity with molten non-ferrous alloys reduce contamination and extend mold life compared to alternatives, which shows up directly in both casting quality and cost per part.

A customer bringing us a part that has historically been cast in steel is usually surprised by how little the conversation changes on the shop floor. The tooling and pour temperature adjust, but the finishing and machining steps that follow stay largely the same.