Walcast is a foundry specialized in the manufacture of tools for various industries worldwide. The foundry, in addition to traditional sand casting, is distinguished by a refractory ceramic casting process. In the 1970s, this process was applied to the manufacture of beryllium copper molds for plastic injection. This process was then improved to develop tools and accessories for hot working in the glass industry.

Manufacturing is similar to that used in traditional foundry, but the sand is replaced by a refractory mixture that obtains all its qualities after a few hours of high-temperature firing in a neutral atmosphere. Thanks to this process, the molds have dimensional precision, reducing machining and finishing operations. It is possible to reproduce very fine skin textures, in relief or in hollow, directly from the foundry. The easy design of the foundry models also allows us to obtain complex shapes. The melting of all our ferrous alloys is done using a medium frequency 300 KG induction furnace. If necessary, the melting can be done under argon. We have three Inductotherm furnaces, which prevent our alloys from being contaminated with undesirable components. The melting of non-ferrous metals is done using a gas-fired Hindenlang furnace with a capacity of 300 Kg.

The following elements allow us to obtain a degree of micrographic cleanliness:

• the use of prefabricated alumina crucibles,
• the use of transfer ladles made in-house with high alumina content,
• the use of zirconium sponge filters up to 60 PPI.
• the use of ingots with a very low percentage of non-metallic inclusions.

To improve the phenomenon of thermal fatigue, which is one of the causes of the degradation of the surface of materials working at high temperatures and subjected to heating and cooling cycles, we perform various heat treatments, in atmosphere, to respect the stages of metallurgical transformation. These treatments are essential to achieve the required homogeneity.

• Hot Isostatic Pressure
• Homogenization
• Quenching
• Tempering

• Refractory steel for hot work: AISI 431 – AISI 420 – AISI H11 – AISI 310.
• Stainless steel: AISI 304 – AISI 316.
• Ni/Cr/Mo alloyed cast irons.
• Non-ferrous alloys based on aluminum and copper.

We want to maintain direct contact with engineers and mold technicians to share our 50 years of experience in the industrial and glass sectors. We have made great efforts to develop and improve our manufacturing technology, which is now recognized worldwide thanks to the tenacity of Mr. Joseph Ortogni, founder of the family business.