Castings - Steel and Nonferrous
Foundry production of ferrous and nonferrous castings applying the sand-casting and air-set processes use Series 300 and 400 stainless steel, high-strength stainless steel, special stainless alloys, nickel alloys, manganese-bronze, aluminum-bronze and other bronze alloys.
Metals shaped in ingots and other forms are melted in electric induction furnaces to a molten or liquid state. When the alloy reaches the optimum pouring temperature, it is moved to a molding area.
An engineered mix of sand and bentonite clay is used as the medium for molds. Plates with single or multiple forms of the actual part to be made are placed in the molding flask and are then surrounded with the sand mixture.
The pattern creates an impression in the mold that will be filled by the molten metal. Any negative impression or internal openings will be created in the casting using cores. These cores are forms made from sand and various binding agents that hold the sand together until the metal form has solidified.
Castings weighing from 1/2 lb to 500 lbs can be made with this process. Casting provides a near-finished form compared to a welded assembly or fabrication. Also, through the casting process a significant amount of machining is eliminated when compared to parts made from bar stock.
On the quality front, the Spal Process (a controlled atmosphere melting process) generates metal free of harmful oxides and gases that are a major source of casting rejects.
The steps described in this sand-casting process yield savings by reducing machining and weld assemblies. The Spal Process helps cut cost by a reduction in rework and scrap levels.
The castings produced by this method are used in valves, pumps, dairy and food processing equipment, marine components, military applications, rail equipment, buildings, heat and furnace treatment units, paper and pulp processing systems, petrochemical facilities, plating systems and power plants.
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