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

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Presentation on theme: ""FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We’re Here). "FOUNDRIES IN NORTHERN."— Presentation transcript:

1 "FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We’re Here). "FOUNDRIES IN NORTHERN CALIFORNIA??" An Overview of Your Neighborhood Aluminum, Brass, Iron, and Steel Foundries (and Why We’re Here).

2 Why? What keeps these foundries here? What keeps these foundries here? Local Designers Local Designers Local Start-ups Local Start-ups Local OEM’s Specialized in their Niche Products and Services. Local OEM’s Specialized in their Niche Products and Services. Medical Capital Equipment Medical Capital Equipment Semi-conductor Capital Equipment Semi-conductor Capital Equipment Networking Enclosures & Equipment Networking Enclosures & Equipment Heavy Trucking Components Heavy Trucking Components Oil Exploration Equipment Oil Exploration Equipment Indoor & Outdoor Lighting Indoor & Outdoor Lighting Why are there only a small number remaining in Northern CA? Why are there only a small number remaining in Northern CA? There were approximately 125 Foundries in 1940’s There were approximately 125 Foundries in 1940’s Consumer items after WWII Consumer items after WWII Less than 20 in 2007 Less than 20 in 2007 Foundries have moved Outside of California Foundries have moved Outside of California Closed Global Competition Closed Global Competition

3 Who? Aluminum Aluminum California Casting - Richmond California Casting - Richmond California State University - Chico California State University - Chico Castco - San Leandro Castco - San Leandro East Bay Brass Foundry - Richmond (Brass, Bronze, Lead, Copper) East Bay Brass Foundry - Richmond (Brass, Bronze, Lead, Copper) Exper Cast Foundry - Santa Clara Exper Cast Foundry - Santa Clara General Foundry Service - San Leandro General Foundry Service - San Leandro Kearney Pattern Works & Foundry – San Jose Kearney Pattern Works & Foundry – San Jose Production Pattern & Foundry Ridge Cast Metals Carson City, NV Production Pattern & Foundry Ridge Cast Metals Carson City, NV Terminal Brass/Aluminum Foundry – South San Francisco Terminal Brass/Aluminum Foundry – South San Francisco Iron McWane Inc - AB&I 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

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

6 Bonded Sand Processes Green Sand Green Sand Chemically Bonded Sand – “No Bake” Chemically Bonded Sand – “No Bake”

7 Green Sand Molding

8 Green Sand Components Sand Sand Clay Clay Water Water Additives Additives Carbons Carbons Cellulose Cellulose Cereals Cereals

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12 Green Sand Molding

13 Green Sand Advantages Cost effective Cost effective Not “hazardous” waste in landfills Not “hazardous” waste in landfills Minimal VOC’s emitted during pouring Minimal VOC’s emitted during pouring Versatile; By far, most widely used Versatile; By far, most widely used Applicable to all alloys except Ti & Zr Applicable to all alloys except Ti & Zr Adaptable to both low and high volume Adaptable to both low and high volume Forgiving of minor tooling flaws Forgiving of minor tooling flaws Steel ice cleat cast in green sand replaced a forging Ductile iron air scoop replaced weldment at 40% cost reduction

14 When Would Green Sand Be Used? Lost Foam 8

15 No Bake Molding

16 No Bake Advantages Also called Air-Set or Self-Setting Also called Air-Set or Self-Setting Used to make cores & molds Used to make cores & molds Easy sand mix compared to green sand Easy sand mix compared to green sand Good sand flowability Good sand flowability Uniform strength in cores & molds Uniform strength in cores & molds Good dimensional control Good dimensional control Dry; No Moisture in mold = Steam Dry; No Moisture in mold = Steam Longer “shelf life” than Greensand Longer “shelf life” than Greensand Can make any size mold or core Can make any size mold or core Strut Fan Cowl Support Beam for Boeing—Aluminum no-bake mold; holds engine to wing

17 When Would No-Bake (Air-Set) Be Used? Lost Foam 8

18 Shell Sand Process

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20 Shell Sand Advantages Holds tight tolerances Holds tight tolerances Less draft required Less draft required Very thin walled sections possible Very thin walled sections possible Small cored holes easily cast Small cored holes easily cast Excellent surface finish Excellent surface finish Excellent dimensional capability Excellent dimensional capability Excellent dimensional stability Excellent dimensional stability

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

22 When Would Shell Molds/Cores Be Used? Lost Foam 8

23 Permanent Molding Permanent Mold Permanent Mold Semi-Permanent Mold Semi-Permanent Mold Low-Pressure Die Casting 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 Static Pouring similar to sand casting similar to sand casting Tilt Pouring 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 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 Low Pressure or Vacuum metal is drawn from below the mold up into the mold (counter gravity ) via a vacuum or pressure metal is drawn from below the mold up into the mold (counter gravity ) via a vacuum or pressure

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

28 Permanent Mold Drawbacks High cost of tooling High cost of tooling Limited casting size Limited casting size

29 When Would Permanent Molds Be Used? Lost Foam 8

30 Plaster Molding

31 Plaster Molding Process Mold is made from a mixture of plaster, talc, other refractory materials and water 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 Slurry is poured or piped into a flask containing the pattern Mold is dried in a circulating air oven until no moisture is present Mold is dried in a circulating air oven until no moisture is present

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33 Plaster Mold Casting Rubber Plaster Mold processRubber Plaster Mold process Commonly replaces plastic injection molding with aluminum castingCommonly replaces plastic injection molding with aluminum casting Natural EMI RF ShieldingNatural EMI RF Shielding Tolerances: +/ ” first 8 inches.Tolerances: +/ ” first 8 inches. 20 days from CAD files to delivery (inc. machining)20 days from CAD files to delivery (inc. machining)

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

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

36 What Is a Common Use for Plaster Molds? Lost Foam 8

37 Investment Casting

38 Ceramic Shell Process

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40 Investment Casting Advantages Extremely accurate & flexible design parameters Extremely accurate & flexible design parameters Useful for casting difficult to machine alloys Useful for casting difficult to machine alloys Superior casting finish Superior casting finish Suitable for large or small quantities Suitable for large or small quantities Wide range of alloys cast 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 Casting size is limited Costly process Costly process Equipment Equipment Patterns Patterns Process components very important Process components very important Additional quality checks required Additional quality checks required

42 When Would Investment Casting Be Used? Lost Foam 8

43 Centrifugal Casting

44 “True” Centrifugal Casting Casting is spun on its own axis Casting is spun on its own axis No risers are required No risers are required No center core is needed No center core is needed

45 Centrifugal Casting Machine Developed ~1923

46 Pipe Casting Machine Iron Flowing into the Mold at ~2340°F. 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 Mold impressions are grouped around a central down-gate Centrifugal force is used as a mold filling device Centrifugal force is used as a mold filling device

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

49 Centrifugal Casting Drawback Limitations on casting shape

50 What Questions Remain About Processes? Lost Foam 8

51 Value to both the manufacturer and the end user, is for the engineer to communicate 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. Value to both the manufacturer and the end user, is for the engineer to communicate 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 from an engineer asking for input during part design. 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 from an engineer asking for input during part design. - East Bay Brass

52 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. 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 x4

53 Digital Mold and Core Printing System Technikon is advancing rapid prototyping technologies, such as digital manufacturing... Technikon is advancing rapid prototyping technologies, such as digital manufacturing... Production digital mold and core printing system Production digital mold and core printing system Prototype casting capability – CAD file to finish castings without tooling 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 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 (925)

54 Local Foundries Aluminum Aluminum California Casting - Richmond California Casting - Richmond California State University - Chico California State University - Chico Castco - San Leandro Castco - San Leandro East Bay Brass Foundry - Richmond (Brass, Bronze, Lead, Copper) East Bay Brass Foundry - Richmond (Brass, Bronze, Lead, Copper) Exper Cast Foundry - Santa Clara Exper Cast Foundry - Santa Clara General Foundry Service - San Leandro General Foundry Service - San Leandro Kearney Pattern Works & Foundry – San Jose Kearney Pattern Works & Foundry – San Jose Production Pattern & Foundry Ridge Cast Metals Carson City, NV Production Pattern & Foundry Ridge Cast Metals Carson City, NV Terminal Brass/Aluminum Foundry – South San Francisco Terminal Brass/Aluminum Foundry – South San Francisco Cast Iron Ridge Foundry – San Leandro Lodi Iron Works - Lodi Centrifugal Iron McWane Inc - AB&I 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


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