SUPERALLOYS

SUPERALLOYS

Doncasters has positioned itself to become one of the world’s largest and most respected superalloy manufacturers.

Our advanced alloys are used across a wide range of performance critical applications as diverse as turbine blades and vanes and other components for aero engines and land-based gas turbines, ‘hot-end’ turbocharger wheels, medical prosthesis and other special components requiring high metallurgical integrity.

Doncasters’ production facilities excel at vacuum and air induction melting. All use the highest quality materials and guarantee the highest level of technical control, ensuring a consistent product with a repeatable tightly controlled chemistry.

Our process expertise in raw material capability, alloy verification, metallurgical R&D and know-how make us a world leader in our field.

Melting critical superalloys under high vacuum conditions demands tight controls and strict adherence to approved manufacturing procedures. Everything, from the selection of raw materials to vacuum pressures, vacuum leak rates, melting and refining practices and pouring techniques, is closely monitored against standard operating procedures and internal specifications to ensure quality is never compromised.

Rigid control of highly reactive elements, distillation of volatile impurities and maintenance of melt quality can only be achieved by the strict application of process controls developed through many years’ experience in producing complex vacuum melted superalloys.

Conventional furnace pouring techniques have been refined to ensure that the molten alloy from the furnace enters the moulds via proprietary designed high quality refractory monolithics and filter systems that maximise alloy quality and cleanliness, at the same time minimising central shrinkage using the latest solidification technology.

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Manufacturing Facilities

Our air melt facilities at Ross & Catherall and Long Beach, CA, operate numerous air induction melting furnaces allowing them to offer customers a wide range of yield weights from 1,102 – 5,070 lb (500 to 2,300 kg). A comprehensive range of iron, nickel and cobalt based alloys can be produced either to individual customer requirements or to internationally accepted specifications as required.

The production of air-melted superalloys involves a fully automatic metal mould casting machine delivering moulds to two pouring stations. By utilising two stations, overall pouring times are reduced to a minimum ensuring close control of chemistry throughout the heat. Coated metal moulds ensure a high standard of barstock surface finish.

Typical open bar poured weights are 6.6 – 11 lb (3-5 kg), but varying bar weights from 5.5 – 13.2 lb (2.5 – 6 kg) can be poured to suit customers’ individual requirements.

All air-melted ingots are shotblasted, individually inspected and marked before packing and dispatch.

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Manufacturing Facilities

FACILITIES SERVING SUPERALLOYS