Scope

To outline the technical and commercial nature of castings in relationship to Machining claims and to explain our company policy which is generally in line with the Foundry Industry in general. It is hoped that it will cause a better understanding between our Company and our Customers.

We would like to explain the reasons behind our policy of not being able to accept machining claims and why we limit our liability to replacement, repair or refund (at our option) of the castings of our supply.

A) There is no allowance provided in our pricing that allows for machining claims. If we did so the price of castings that are to be subsequently machined would rise substantially. Moreover a detailed evaluation of the capabilities of the machinist and the requirements the end user expects from the finished product would be necessary on an individual casting basis. This is not a practical proposition for us as a supplier of commercial castings.

B) Frequently we do not know that a specific casting is to be machined and where suitable machining allowances are to be provided. We supply many castings purely from the pattern supplied. If your casting is to be machined please let us have a copy of the machined component drawing. Also advise us of any specific important areas requiring better that commercial soundness when we can evaluate our production process to accommodate your requirements to a better degree than otherwise. This may cause pattern changes to be made and we will advise any extra costs for this before proceeding.

C) You may better appreciate our position in the case where machining costs outweighs the price of the casting by several times!! The solution is to choose your foundry very carefully and work closely with him to develop an acceptable product and to make appropriate unrecoverable cost allowances given the nature of the cast product.

D) We are not in technical or commercial control of the machining process. We are unable to either pre-determine the machining sequence or to stop machining (to reduce costs) at the earliest possible moment. Our experience is that many machine shops will press ahead without any interstage inspection and if the final product is scrap that is not their concern. They expect to get paid for all work performed by them even if the final product is unusable – and if they can blame the foundry ……!! Sometimes castings are capable of “cleaning up” if machined in a pre-determined sequence and controlled cuts and from specified datums. Moreover the foundry, having considered all aspects of the casting, is in the best position to specify machining allowances. Frequently end user and machine shops have unrealistic ideas about machining allowances.

E) We supply over 300 alloys in various metallurgical conditions. The ability of a machine shop to machine ferrous materials other than mild steel varies considerably.

F) Our standard quotation allows for the repair of castings by welding. If that is not acceptable to you then advice us accordingly before production commences but be aware that this may well cause the price of the casting to rise substantially. It may then be possible at our option and cost to repair faulty part-machined casting by welding especially were the casting is of high value thus saving the situation to mutual benefit. This is strictly at our option.

G) If you have specific quality standards please advise us accordingly before production commences. We are unable to second guess unspecified requirements.

H) Consider carefully what type and level of testing you require to produce the level of integrity you require. However please consider that every step taken to produce a higher integrity casting substantially lifts the price as costing is not only a function of the cost of the testing but also the extra manufacturing costs to produce that quality and a higher than normal production reject rate. Most tests, especially non-destructive tests, do not detect all defects at all levels and passing such a test does not ensure defect free castings!

I) Please be aware that unlike wrought products that have very high levels of inherent defect free integrity practically all castings contain inherent defects. The management of the level, type and position of such defects requires close co-operation between the manufacturer and customer and frequently this is a multi staged development programme to more closely provide castings of acceptable quality. No commercial jobbing foundry is able to supply zero defect castings. It is the nature of the process that not all castings, even if produced at the same time, are technically identical.

J) There is huge difference in quality and costings of castings dependant upon integrity levels required. Consider a cast iron decorative panel and a single crystal jet engine turbine blade!! What do you really need?

K) Non of the foregoing precludes customer inspection of our product before commencing acceptance for machining or any other further processes

L) Finally, we can quote you on the supply of machined casting which eliminates the problem of unrecoverable machining costs as we will absorb such costs within our quoted price.

Austral Alloys Pty Ltd 174-176 Eldridge Road

BANKSTOWN NSW 2200 Australia

A B N 15 058 591 647

Telephone (02) 9790 5110 Fax (02) 9790 2186

Scope

Austral Alloys Pty Ltd 174-176 Eldridge Road

custserv@australalloys.com.au

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