"FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We - PowerPoint PPT Presentation

Loading...

PPT – "FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We PowerPoint presentation | free to download - id: 683a31-ODVlZ



Loading


The Adobe Flash plugin is needed to view this content

Get the plugin now

View by Category
About This Presentation
Title:

"FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We

Description:

Title: Green Sand Vertically-Parted Molds Author: David Kanicki Last modified by: Keith Krook Created Date: 3/29/1999 10:40:36 PM Document presentation format – PowerPoint PPT presentation

Number of Views:1
Avg rating:3.0/5.0
Date added: 30 July 2019
Slides: 55
Provided by: DavidKa156
Learn more at: http://web.stanford.edu
Category:

less

Write a Comment
User Comments (0)
Transcript and Presenter's Notes

Title: "FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We


1
"FOUNDRIES IN NORTHERN CALIFORNIA??" An
Overview of Your Neighborhood Aluminum, Brass,
Iron, and Steel Foundries (and Why Were Here).
2
Why?
  • What keeps these foundries here?
  • Local Designers
  • Local Start-ups
  • Local OEMs Specialized in their Niche Products
    and Services.
  • Medical Capital Equipment
  • Semi-conductor Capital Equipment
  • Networking Enclosures Equipment
  • Heavy Trucking Components
  • Oil Exploration Equipment
  • Indoor Outdoor Lighting
  • Why are there only a small number remaining in
    Northern CA?
  • There were approximately 125 Foundries in 1940s
  • Consumer items after WWII
  • Less than 20 in 2007
  • Foundries have moved Outside of California
  • Closed Global Competition

3
Who?
  • Iron
  • McWane Inc - ABI Foundry Oakland
  • Ridge Foundry San Leandro
  • Lodi Iron Works - Lodi
  • U S Pipe Foundry - Union City
  • Steel
  • California Electric Steel Angels Camp
  • Grass Valley Steel Cast - Grass Valley
  • Pacific Steel Berkeley
  • Tusco Casting Lodi
  • Specialty Services
  • Rapid Mold (Digitized Molding) Most Alloys
    Poured
  • St. John Associates
  • Aluminum
  • California Casting - Richmond
  • California State University - Chico
  • Castco - San Leandro
  • East Bay Brass Foundry - Richmond (Brass,
    Bronze, Lead, Copper)
  • Exper Cast Foundry - Santa Clara
  • General Foundry Service - San Leandro
  • Kearney Pattern Works Foundry San Jose
  • Production Pattern Foundry Ridge Cast Metals
    Carson City, NV
  • Terminal Brass/Aluminum Foundry South San
    Francisco

4






 









 


 




5
Processes
  • Bonded Sand Casting
  • Green Sand
  • Chemically Bonded Sand
  • Vacuum Casting
  • Shell Sand Casting
  • Permanent Mold Casting
  • Rubber Plaster Mold (RPM) Casting
  • Investment Casting
  • Centrifugal Casting
  • True Centrifugal
  • Centrifugal

6
Bonded Sand Processes
  • Green Sand
  • Chemically Bonded Sand No Bake

7
Green Sand Molding
8
Green Sand Components
  • Sand
  • Clay
  • Water
  • Additives
  • Carbons
  • Cellulose
  • Cereals

9
(No Transcript)
10
(No Transcript)
11
(No Transcript)
12
Green Sand Molding
13
Green Sand Advantages
Steel ice cleat cast in green sand replaced a
forging
  • Cost effective
  • Not hazardous waste in landfills
  • Minimal VOCs emitted during pouring
  • Versatile By far, most widely used
  • Applicable to all alloys except Ti Zr
  • Adaptable to both low and high volume
  • Forgiving of minor tooling flaws

Ductile iron air scoop replaced weldment at 40
cost reduction
14
When Would Green Sand Be Used?
15
No Bake Molding
16
No Bake Advantages
  • Also called Air-Set or Self-Setting
  • Used to make cores molds
  • Easy sand mix compared to green sand
  • Good sand flowability
  • Uniform strength in cores molds
  • Good dimensional control
  • Dry No Moisture in mold Steam
  • Longer shelf life than Greensand
  • Can make any size mold or core

Strut Fan Cowl Support Beam for BoeingAluminum
no-bake mold holds engine to wing
17
When Would No-Bake (Air-Set) Be Used?
18
Shell Sand Process
19
(No Transcript)
20
Shell Sand Advantages
  • Holds tight tolerances
  • Less draft required
  • Very thin walled sections possible
  • Small cored holes easily cast
  • Excellent surface finish
  • Excellent dimensional capability
  • Excellent dimensional stability

21
Shell Sand Drawbacks
  • Special pattern equipment required
  • Capital outlay for machinery
  • Size limits - small to medium sized molds cores
  • Resin level is slightly higher than other
    chemically bonded sands
  • High casting volume needed for cost efficiency

22
When Would Shell Molds/Cores Be Used?
23
Permanent Molding
  • Permanent Mold
  • Semi-Permanent Mold
  • Low-Pressure Die Casting

24
Interchangeable Terms
  • Permanent Mold
  • Low Pressure Permanent Mold
  • Die Casting
  • Gravity Die Casting
  • Low Pressure Die Casting
  • High Pressure Die Casting

Confused Yet?
25
Permanent Mold Casting
26
Types of Permanent Mold Casting
  • Static Pouring
  • similar to sand casting
  • Tilt Pouring
  • metal is poured into a basin while mold is
    horizontal and flows into the mold cavity as the
    mold is gradually tilted to a vertical position
  • Low Pressure or Vacuum
  • metal is drawn from below the mold up into the
    mold (counter gravity ) via a vacuum or pressure

27
Permanent Mold Advantages
Oscar-Copper-based alloy
  • Good dimensional accuracy
  • Consistent quality
  • Metal fill can be controlled (tilt-pour)
  • Suitable for fairly complex castings
  • Multiple alloys castable
  • Expendable cores can be used
  • Process is then called Semi-Permanent mold

Corvette Brake Pedal-converted from steel to
aluminum
28
Permanent Mold Drawbacks
  • High cost of tooling
  • Limited casting size

29
When Would Permanent Molds Be Used?
30
Plaster Molding
31
Plaster Molding Process
  • Mold is made from a mixture of plaster, talc,
    other refractory materials and water
  • Slurry is poured or piped into a flask containing
    the pattern
  • Mold is dried in a circulating air oven until no
    moisture is present

32
(No Transcript)
33
Plaster Mold Casting
  • Rubber Plaster Mold process
  • Commonly replaces plastic injection molding with
    aluminum casting
  • Natural EMI RF Shielding
  • Tolerances /- 0.010 first 8 inches.
  • 20 days from CAD files to delivery (inc.
    machining)

34
Plaster Advantages
  • High casting yield
  • no gas or steam produced when metal is poured
  • Fine detail intricate thin sections possible
  • Very little cleaning, if any, needed

35
Plaster Drawbacks
  • Drying time can take hours and can cause warpage
    or shrinkage of the mold
  • Low to medium volume production capabilities
  • Limited alloys - usually nonferrous

36
What Is a Common Use for Plaster Molds?
37
Investment Casting
38
Ceramic Shell Process
39
(No Transcript)
40
Investment Casting Advantages
  • Extremely accurate flexible design parameters
  • Useful for casting difficult to machine alloys
  • Superior casting finish
  • Suitable for large or small quantities
  • Wide range of alloys cast

Cast in Stainless or Chrome-Moly Steel for
Integrity, Cast-In Features and Aesthetics All
Ruger Castings Are Visible
41
Investment Casting Drawbacks
  • Casting size is limited
  • Costly process
  • Equipment
  • Patterns
  • Process components very important
  • Additional quality checks required

42
When Would Investment Casting Be Used?
43
Centrifugal Casting
44
True Centrifugal Casting
  • Casting is spun on its own axis
  • No risers are required
  • No center core is needed

45
Centrifugal Casting MachineDeveloped 1923
46
Pipe Casting MachineIron Flowing into the Mold
at 2340F.
  • Plant produces about
  • 4 miles of pipe/day.
  • Pipe are approximately 85-90 recycled materials.

47
Centrifuged Casting
  • Mold impressions are grouped around a central
    down-gate
  • Centrifugal force is used as a mold filling device

48
Centrifugal Casting Advantages
  • Improved homogeneity
  • Improved accuracy in special circumstances

49
Centrifugal Casting Drawback
  • Limitations on casting shape

50
What Questions Remain About Processes?
51
  • Value to both the manufacturer and the end
    user, is for the engineer tocommunicate with the
    foundry, fabricator, or whomever during the
    design process. If the drawing calls for a
    fabricated piece they may have missed an
    opportunity for a cast part that may have done a
    superior job, may have cost less, may have been
    quicker.  
  • Or if a casting was called for maybe they
    designed in such a way that the part is 3 times
    as expensive as it would have been had they not
    added an undercut that required extra tooling via
    inserts or multiple core boxes.  We love it when
    we get an email from an engineer asking for input
    during part design.
  • - East Bay Brass

52
www.Lodiiron.com
  • Lodi Iron works has been making quality Iron and
    Steel castings for over 60 years. Centrally
    located in the San Joaquin Valley, LIW is capable
    of pouring 1 pound to 1000 pound castings in any
    Ferrous alloy including Cast Iron or Ductile Iron
    in our Lodi Foundry, and any Steel, Stainless
    Steel or various specialty alloy such as 17-4 PH
    Monel in our Galt Foundry, 10 miles away. We
    have a Pattern Shop on site and are willing to
    help our customers in the design phase of
    projects in order to develop the best combination
    of quality and cost efficiency in the final
    product. We are happy to quote projects of as few
    as one casting but we are also set up to run
    volumes of 1000's of castings on our 3 automated
    production lines. If you need high quality sand
    castings and want to work with a foundry that
    cares about your success, give us a call. 
  • Barron Gage - Sales Manager
  • Lodi Iron Works
  • 209-368-5395 x4

53
Digital Mold and Core Printing System
  • Technikon is advancing rapid prototyping
    technologies, such as digital manufacturing . . .
  • Production digital mold and core printing system
  • Prototype casting capability CAD file to finish
    castings without tooling
  • Development of superior binder technologies are
    being tested to advance digital manufacturing
    mold and core packages
  • Jay S. St. John
  • ST. JOHN ASSOCIATES
  • P.O. Box 323
  • Diablo, CA 94528
  • (925) 984-4677
  • jsstjohn_at_hotmail.com

54
Local Foundries
  • Cast Iron
  • Ridge Foundry San Leandro
  • Lodi Iron Works - Lodi
  • Centrifugal Iron
  • McWane Inc - ABI Foundry Oakland
  • U S Pipe Foundry - Union City
  • Steel
  • California Electric Steel Angels Camp
  • Grass Valley Steel Cast - Grass Valley
  • Pacific Steel Berkeley
  • Tusco Casting Lodi
  • Specialty Services
  • Rapid Mold (Digitized Molding) (Pouring Most
    Alloys)
  • St. John Associates
  • Aluminum
  • California Casting - Richmond
  • California State University - Chico
  • Castco - San Leandro
  • East Bay Brass Foundry - Richmond (Brass,
    Bronze, Lead, Copper)
  • Exper Cast Foundry - Santa Clara
  • General Foundry Service - San Leandro
  • Kearney Pattern Works Foundry San Jose
  • Production Pattern Foundry Ridge Cast Metals
    Carson City, NV
  • Terminal Brass/Aluminum Foundry South San
    Francisco
About PowerShow.com