Artificial lift manufacturer, Manchester, United Kingdom
Industry: Artificial Lifts for Oil & Gas
Application: Downhole Tools; Flow Control
Location: Manchester, United Kingdom
Problem
An artificial lift manufacturer was seeking quality improvement for their 4140 alloy used to produce rotors for progressing cavity pumps. Previously when machining the bars from other sources, stresses would be relieved causing the bars to move. This repeated issue would further lead to increased scrap expenses and reduced productivity in the customer’s workflows.
Solution
This customer worked closely with Castle Metals to establish the exact 4140 alloy quality they required. Castle then worked with its in-house heat treater in North America to determine how to create the product at the exact mechanical requirements, while consistently producing the same piece. The 360° horizontal quench and temper process done by Castle Metals produces a perfectly tight tolerance for this customer (.007” to .009” depending on size) while ensuring a consistent output without adding more stress to the metal (which is necessary for the highly corrosive final product). Now the raw material comes from a North American mill, is heat-treated, turned and polished at Castle Metals, and is then shipped to the Manchester location.
Result
Because of the 360° horizontal quench and tempering process, the final product is consistently produced at the same, superior quality. This specific 4140 quenched and tempered, turned and polished bar from Castle Metals is of a quality that cannot be produced elsewhere to supply this customer.