In the high-precision sector of investment casting (lost-wax casting), quality is non-negotiable. To supply reliable, repeatable metal components that comply with international standards, rigorous control at every stage of the process is essential.
EDR FITTINGS SRL, an ISO 9001:2015 certified company supported by a network of highly qualified partners, has integrated an advanced system of technical controls that ensures top-level products for both Italian and international markets. The combination of Industry 4.0 technologies, specialized personnel, and strict quality protocols guarantees high standards and continuous process improvement.
Investment Casting: Process and Quality Requirements
Investment casting is an advanced production technique capable of creating metal components with:
- Complex geometries: Reduced need for subsequent mechanical machining.
- Tight tolerances: High dimensional accuracy.
- Superior surface finishes: Excellent aesthetic and functional appearance.
This process is essential in critical sectors such as Automotive, Precision Mechanics, Energy, Marine, and Luxury. Due to its intrinsic complexity, it requires a structured and continuous quality control system from wax modelling to pouring and finally to the final inspections.
The Pillars of the EDR FITTINGS SRL Quality Control System
The control system of EDR FITTINGS is based on four integrated verification levels, ensuring total product integrity.
1. Initial Visual and Instrumental Inspection
This is the first and continuous level of verification, performed by certified operators and/or advanced artificial vision systems.
Objective: Detect surface and macroscopic defects both in-process and post-process.
Defects detected: Surface cracks, porosity, visible inclusions, deformations, and aesthetic non-conformities.
2. Dimensional Control (Metrology)
Verification of full compliance with the technical drawing specifications and critical tolerances.
Traditional Instrumentation: Calipers, micrometers, and precision comparators.
Advanced Metrology: Use of Coordinate Measuring Machines (CMM) for extremely accurate 3D measurements.
Series Production: Application of Statistical Process Control (SPC) to monitor production stability and drift.
3. Non-Destructive Testing (NDT)
Crucial techniques used to verify the internal integrity of the component without altering its functionality – ideal for critical applications.
- Penetrant Testing (PT): Identification of surface discontinuities such as cracks and pores.
- Magnetic Particle Testing (MT): Detection of subsurface flaws in ferromagnetic materials.
- Radiography (RX) and Ultrasonic Testing: Verification of the absence of porosity, inclusions, and internal defects.
4. Mechanical Tests and Material Analyses
Evaluations carried out to confirm the physical properties and strength of the cast material.
- Mechanical Tests: Tensile tests (breaking load, yield strength), impact tests (resilience), and hardness measurements (Brinell, Rockwell, Vickers).
- Metallographic Analyses: Microstructural checks to ensure that the composition and structure comply with technical standards.
Quality Management and Industry 4.0 Technologies
EDR FITTINGS adopts a prevention-based, data-driven approach aligned with Industry 4.0 principles.
A. Structured Control Planning
- Risk Analysis: Detailed assessment of specifications, regulations (e.g., DNV for the marine sector), critical geometries, and customer requirements.
- Control Protocol: Development of a complete Control Plan defining preliminary, in-process, and final controls, together with sampling plans and acceptance criteria.
B. Advanced Monitoring Technologies
- Artificial Vision Systems: Automatic surface inspection, minimizing human error and ensuring consistency.
- IoT Sensors: Real-time monitoring of critical casting parameters (temperatures, viscosity, vibrations), enabling proactive anomaly management.
- Advanced Data Analysis: Use of dedicated software for Predictive Diagnostics, Statistical Process Control, and optimization of casting parameters.
C. Expertise and Training
Quality is ensured by human capital. Personnel undergo continuous training through qualified institutions such as AQM®, maintaining a high and up-to-date technical level.
Customer Benefits
- Reliability and Repeatable Quality: Components that are 100% compliant in every production batch.
- Scrap Reduction: Process optimization and cost control.
- Complete Traceability: Transparent documentation of every production and inspection phase.
- Regulatory Compliance: Suitable for the most demanding and critical applications.
- Technical Reputation: A solid partner with a certified and recognized quality system.
EDR FITTINGS SRL does not consider quality an occasional achievement, but a constant commitment guiding every company activity, establishing itself as a reliable and competent partner in the investment casting sector.
