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IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSION Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
INDIANA START-UP TO CAST RAILROAD PARTS Indiana Start-Up to Cast Railroad Parts. Documents filed in behalf of a new business describe a highly automated, steel scrap-melting operation to begin operating this year. Jan 21, 2020. Brinco, a Delaware-based company, plans to launch operations at a former Chassix plant in Bristol, IN, to produce steel castings for rail markets. ROBOTIC GRINDING CELL FOR HEAVY PARTS Recently, a manufacturer of steel parts that weigh up to 3,000 lbs. (and larger) asked Vulcan Engineering Co. to improve the heavy grinding in its finishing operation. Vulcan designed and built a robotic grinding cell, centered on a foundry-duty robot together with measurement and software technologies to handle the dimensional variations inherent in the customer’s process. UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSION Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
INDIANA START-UP TO CAST RAILROAD PARTS Indiana Start-Up to Cast Railroad Parts. Documents filed in behalf of a new business describe a highly automated, steel scrap-melting operation to begin operating this year. Jan 21, 2020. Brinco, a Delaware-based company, plans to launch operations at a former Chassix plant in Bristol, IN, to produce steel castings for rail markets. ROBOTIC GRINDING CELL FOR HEAVY PARTS Recently, a manufacturer of steel parts that weigh up to 3,000 lbs. (and larger) asked Vulcan Engineering Co. to improve the heavy grinding in its finishing operation. Vulcan designed and built a robotic grinding cell, centered on a foundry-duty robot together with measurement and software technologies to handle the dimensional variations inherent in the customer’s process. UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
FOUNDRY MAGAZINE
Foundry Management & Technology – June 2019. Foundry Magazine. May 2019. May 06, 2019. Foundry Management & Technology – May 2019. Foundry Magazine. April 2019. Apr 11, 2019. Foundry Management & Technology – April 2019. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
FOR INVESTMENT CASTERS, FOAM PATTERNS For Investment Casters, Foam Patterns. These artificial hip-joint castings are made using a foam pattern known as FoPat, which makes it possible to produce castings with no pattern-removal step, eliminating the use of steaming to remove wax patterns. A shroud segment showing wax (bottom) and FoPat (top) patterns. NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. CONTINUOUS IMPROVEMENT IN FOUNDRY PROCESSES Step 1: Create a high-level process map to identify and name the core processes in the foundry. A high-level process map is a block diagram showing the sequences of processes, such as patternmaking, molding and coremaking, melting and pouring, cleaning, and finishing, including heat treatment and welding. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
6 REASONS WHY “SMART” GOAL-SETTING DOES NOT WORK You’re probably familiar with the concept of Smart goals. “Smart” is an acronym for ideas, tactics, or methods that are developed to be 1) specific, 2) measurable, 3) achievable, 4) realistic, and 5) time-bound. Organizations use Smart goals for two reasons. When addressing each aspect identified by the acronym, the anticipated result is UNDERSTANDING ADV AND PH TESTING FOR MOLD, CORE SAND The pH test for foundry sands uses 25.0 grams of sand mixed with 100 ml of distilled or deionized water adjusted to pH of 7. The sand and water is stirred for five minutes before the pH of the water is measured. The detailed method for determining pH of sand is found in The Mold and Core Test Handbook, 3rd Edition, AFS 5113-00-S. UNDERSTAND THE EFFECTS OF ZINC PENETRATION ON INDUCTION Melt/Pour; Understand the Effects of Zinc Penetration on Induction Furnace Linings and How to Compensate for It. Galvanized steel scrap may be a source of iron units for foundries, and a source of contamination to refractory linings Diminishing electrical impedance Counteracting lining deformation Compensating in four steps BRADKEN TO EXPAND TACOMA FOUNDRY Apr 05, 2011. Bradken’s Energy Business, the onetime Atlas Castings and Technology foundry in Tacoma, WA, will be the site of a $23-million expansion aimed at increasing space for producing large-scale castings, and adding capacity for radiographic testing. The schedule for the expansion has not been detailed. HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSION Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
INDIANA START-UP TO CAST RAILROAD PARTS Indiana Start-Up to Cast Railroad Parts. Documents filed in behalf of a new business describe a highly automated, steel scrap-melting operation to begin operating this year. Jan 21, 2020. Brinco, a Delaware-based company, plans to launch operations at a former Chassix plant in Bristol, IN, to produce steel castings for rail markets. ROBOTIC GRINDING CELL FOR HEAVY PARTS Recently, a manufacturer of steel parts that weigh up to 3,000 lbs. (and larger) asked Vulcan Engineering Co. to improve the heavy grinding in its finishing operation. Vulcan designed and built a robotic grinding cell, centered on a foundry-duty robot together with measurement and software technologies to handle the dimensional variations inherent in the customer’s process. UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSION Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
INDIANA START-UP TO CAST RAILROAD PARTS Indiana Start-Up to Cast Railroad Parts. Documents filed in behalf of a new business describe a highly automated, steel scrap-melting operation to begin operating this year. Jan 21, 2020. Brinco, a Delaware-based company, plans to launch operations at a former Chassix plant in Bristol, IN, to produce steel castings for rail markets. ROBOTIC GRINDING CELL FOR HEAVY PARTS Recently, a manufacturer of steel parts that weigh up to 3,000 lbs. (and larger) asked Vulcan Engineering Co. to improve the heavy grinding in its finishing operation. Vulcan designed and built a robotic grinding cell, centered on a foundry-duty robot together with measurement and software technologies to handle the dimensional variations inherent in the customer’s process. UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
FOUNDRY MAGAZINE
Foundry Management & Technology – June 2019. Foundry Magazine. May 2019. May 06, 2019. Foundry Management & Technology – May 2019. Foundry Magazine. April 2019. Apr 11, 2019. Foundry Management & Technology – April 2019. FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
FOR INVESTMENT CASTERS, FOAM PATTERNS For Investment Casters, Foam Patterns. These artificial hip-joint castings are made using a foam pattern known as FoPat, which makes it possible to produce castings with no pattern-removal step, eliminating the use of steaming to remove wax patterns. A shroud segment showing wax (bottom) and FoPat (top) patterns. NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. CONTINUOUS IMPROVEMENT IN FOUNDRY PROCESSES Step 1: Create a high-level process map to identify and name the core processes in the foundry. A high-level process map is a block diagram showing the sequences of processes, such as patternmaking, molding and coremaking, melting and pouring, cleaning, and finishing, including heat treatment and welding. METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
6 REASONS WHY “SMART” GOAL-SETTING DOES NOT WORK You’re probably familiar with the concept of Smart goals. “Smart” is an acronym for ideas, tactics, or methods that are developed to be 1) specific, 2) measurable, 3) achievable, 4) realistic, and 5) time-bound. Organizations use Smart goals for two reasons. When addressing each aspect identified by the acronym, the anticipated result is UNDERSTANDING ADV AND PH TESTING FOR MOLD, CORE SAND The pH test for foundry sands uses 25.0 grams of sand mixed with 100 ml of distilled or deionized water adjusted to pH of 7. The sand and water is stirred for five minutes before the pH of the water is measured. The detailed method for determining pH of sand is found in The Mold and Core Test Handbook, 3rd Edition, AFS 5113-00-S. UNDERSTAND THE EFFECTS OF ZINC PENETRATION ON INDUCTION Melt/Pour; Understand the Effects of Zinc Penetration on Induction Furnace Linings and How to Compensate for It. Galvanized steel scrap may be a source of iron units for foundries, and a source of contamination to refractory linings Diminishing electrical impedance Counteracting lining deformation Compensating in four steps BRADKEN TO EXPAND TACOMA FOUNDRY Apr 05, 2011. Bradken’s Energy Business, the onetime Atlas Castings and Technology foundry in Tacoma, WA, will be the site of a $23-million expansion aimed at increasing space for producing large-scale castings, and adding capacity for radiographic testing. The schedule for the expansion has not been detailed. HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. WILL A CO2-CURED COLD BOX BINDER SYSTEM WORK FOR YOU Tensile strength development of Carbophen resin. Carbophen is a water-based alkaline phenolic resin system cured by passing CO 2 gas into a sealed core box. The resin is the sole binder component added to the sand for making cores and molds. Typical binder levels range from 1.5-3.0%, based on sand weight. Recent testing has shown thatbinder
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSIONMOLTEN METAL BATTERYMOLTEN METAL SIGNSMOLTEN LAYER OF EARTHWHAT IS MOLTEN METALCALLED
Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
APPLYING MAGNETICS TO CONTROL LOW-PRESSURE CASTING Applying Magnetics to Control Low-Pressure Casting. Developers claim success at slowing and controlling molten aluminum flow using a magnetic field and a short-circuit current, to optimize high-volume pouring. Pouring molten metal is a precision process during which pouring speed (to achieve high throughput) must be balanced byeffective flow
UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. WILL A CO2-CURED COLD BOX BINDER SYSTEM WORK FOR YOU Tensile strength development of Carbophen resin. Carbophen is a water-based alkaline phenolic resin system cured by passing CO 2 gas into a sealed core box. The resin is the sole binder component added to the sand for making cores and molds. Typical binder levels range from 1.5-3.0%, based on sand weight. Recent testing has shown thatbinder
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSIONMOLTEN METAL BATTERYMOLTEN METAL SIGNSMOLTEN LAYER OF EARTHWHAT IS MOLTEN METALCALLED
Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
APPLYING MAGNETICS TO CONTROL LOW-PRESSURE CASTING Applying Magnetics to Control Low-Pressure Casting. Developers claim success at slowing and controlling molten aluminum flow using a magnetic field and a short-circuit current, to optimize high-volume pouring. Pouring molten metal is a precision process during which pouring speed (to achieve high throughput) must be balanced byeffective flow
UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
ISSUES AND IDEAS
Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. OPTIMIZING CUPOLA SYSTEM DESIGN Melt/Pour; Optimizing Cupola System Design. Stopping molten iron oxidation is the first priority for foundries operating cupola systems. The next step is to initiate the system and melting process changes that will improve iron quality and productivity. COLUMBIANA, AL PLANT TO CLOSE IN AUGUST Grede to Close Alabama Iron Foundry. A notice filed in early June sets the shutdown date for August 10, affecting 94 workers at the Columbiana plant. The decision is based on "market conditions," according to Grede's CEO. Jun 30, 2020. Grede Holding LLC confirmed a local news report of its plan to close the foundry in Columbiana, AL. SHAKEOUT | FOUNDRY MANAGEMENT & TECHNOLOGY Foundry's 2019-2020 Where-to-Buy Directory. Oct 29, 2019. The Foundry Management & Technology Where-To-Buy Directory is designed to help foundries and diecasters locate suppliers for all of their metalcasting needs and purchasing decisions -- quickly and conveniently. Materials. CANEKAST ACQUIRES MORE ALUMINUM CASTING CAPACITY Circular economy, set to be the biggest revolution in the global economy in 250 years according to Accenture, is part of the ongoing narrative on industrial sustainability, which aims to increase the reuse of resources and minimize the generation of waste. Recent economic factors such as input cost rises and resource volatility have heavily influenced this shift toward a circular approach, but IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOR INVESTMENT CASTERS, FOAM PATTERNS For Investment Casters, Foam Patterns. These artificial hip-joint castings are made using a foam pattern known as FoPat, which makes it possible to produce castings with no pattern-removal step, eliminating the use of steaming to remove wax patterns. A shroud segment showing wax (bottom) and FoPat (top) patterns. TOP 10 WAYS TO MAXIMIZE CRUCIBLE SERVICE LIFE 7. Every crucible has a maximum temperature limit. If you exceed that limit the crucible will be damaged and may fail. Keep close control of crucible temperatures. Allowing molten metal to solidify in the crucible also may damage the crucible when that metal is reheated for pouring. 6. Avoid physical damage by charging correctly and carefully. 6 REASONS WHY “SMART” GOAL-SETTING DOES NOT WORK You’re probably familiar with the concept of Smart goals. “Smart” is an acronym for ideas, tactics, or methods that are developed to be 1) specific, 2) measurable, 3) achievable, 4) realistic, and 5) time-bound. Organizations use Smart goals for two reasons. When addressing each aspect identified by the acronym, the anticipated result is REAL-TIME LASER-BASED MOLTEN-METAL MONITORING Real-Time Laser-based Molten-Metal Monitoring. New spectrometry method combines advances in refractory manufacturing and laser metrology to read chemical and temperature changes, without stopping production. All the fortunes of metalcasting companies depend on a series of thermal and chemical reactions that are not quite as predictable asthe
HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. WILL A CO2-CURED COLD BOX BINDER SYSTEM WORK FOR YOU Tensile strength development of Carbophen resin. Carbophen is a water-based alkaline phenolic resin system cured by passing CO 2 gas into a sealed core box. The resin is the sole binder component added to the sand for making cores and molds. Typical binder levels range from 1.5-3.0%, based on sand weight. Recent testing has shown thatbinder
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSIONMOLTEN METAL BATTERYMOLTEN METAL SIGNSMOLTEN LAYER OF EARTHWHAT IS MOLTEN METALCALLED
Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
APPLYING MAGNETICS TO CONTROL LOW-PRESSURE CASTING Applying Magnetics to Control Low-Pressure Casting. Developers claim success at slowing and controlling molten aluminum flow using a magnetic field and a short-circuit current, to optimize high-volume pouring. Pouring molten metal is a precision process during which pouring speed (to achieve high throughput) must be balanced byeffective flow
UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
HOME | FOUNDRY MANAGEMENT & TECHNOLOGYFINISHINGMATERIALSMELT/POURMOLDS/CORESSHAKEOUTSIMULATION/IT Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. FOLLOWING THE TRENDS TO BETTER DESIGNS, BETTER CASTINGS Following the Trends to Better Designs, Better Castings. CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting. One or two technology cycles ago, metalcasters were enthusiastically adopting simulation programs to identify thecauses
FOSECO | FOUNDRY MANAGEMENT & TECHNOLOGY Foseco, Vesuvius Mexico. S.A. de C.V. Carretera a San Miguel KM 1. Col. Jardines de San Rafael CG. 800-718-2030. Fax: 52 (81) 8319-4598. Foseco is a leading manufacturer and provider of proprietary consumable products and solutions to the global foundry industry. We are dedicated to helping customers improve their operations andbusinesses with
METALCASTING GROWTH STRATEGIES II: HOW FOUNDRIES MAKE Metalcasting Growth Strategies II: How Foundries Make their Money. A foundry strategist offers perspectives on metalcasting business models, discusses their merits from a growth strategy perspective. Understanding the competitive dynamics of an industry is a critical part of any growth strategy effort. The metalcasting industry can beanalyzed
NEW HPDC AT MERCURY CASTINGS The new foundry’s furnace is a 110-liter, 130-kW vessel for melting at up to 1,650 °C, with casting pressure up to 1.0 bar. The 1,310 × 1,290 mm 2 lower mounting surface can accommodate molds weighing up to 3,500 kg. The upper mounting surface of 1,200 × 1,200 mm 2 allows a maximum clamping force of 60 metric tons. WILL A CO2-CURED COLD BOX BINDER SYSTEM WORK FOR YOU Tensile strength development of Carbophen resin. Carbophen is a water-based alkaline phenolic resin system cured by passing CO 2 gas into a sealed core box. The resin is the sole binder component added to the sand for making cores and molds. Typical binder levels range from 1.5-3.0%, based on sand weight. Recent testing has shown thatbinder
TREATING MOLTEN METAL TO REDUCE REFRACTORY EROSIONMOLTEN METAL BATTERYMOLTEN METAL SIGNSMOLTEN LAYER OF EARTHWHAT IS MOLTEN METALCALLED
Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. HOT TOPPING TECHNIQUES FOR RISER FEEDING CONSISTENCY Hot Topping Techniques for Riser Feeding Consistency. Floating cover lids can dramatically improve the consistency of a riser's feeding efficiency. Floating cover lids designed to replace traditional powder hot toppings. For years foundries have used various different materials — from silica sand, to rice hulls, to insulating andexothermic
APPLYING MAGNETICS TO CONTROL LOW-PRESSURE CASTING Applying Magnetics to Control Low-Pressure Casting. Developers claim success at slowing and controlling molten aluminum flow using a magnetic field and a short-circuit current, to optimize high-volume pouring. Pouring molten metal is a precision process during which pouring speed (to achieve high throughput) must be balanced byeffective flow
UNDERSTANDING THE CHOICE FOR SEALING POROUS CASTINGS Understanding the Choice for Sealing Porous Castings. Pressure impregnation gives engineers an alternative to vacuum batch impregnation processes: it’s faster, achieves a higher success rate, and has a lower cost per part. Sealing porous leaking castings by pressure impregnation involves the same process as pressure testing,but it uses a
ISSUES AND IDEAS
Anticipating the Challenges of Digital Transformation. May 04, 2021. Automation, robotics, sensors, and different software solutions have completely changed how people interact with equipment, and how products are created. Manufacturers face a double-edged sword of risk and reward. Issues and Ideas. OPTIMIZING CUPOLA SYSTEM DESIGN Melt/Pour; Optimizing Cupola System Design. Stopping molten iron oxidation is the first priority for foundries operating cupola systems. The next step is to initiate the system and melting process changes that will improve iron quality and productivity. COLUMBIANA, AL PLANT TO CLOSE IN AUGUST Grede to Close Alabama Iron Foundry. A notice filed in early June sets the shutdown date for August 10, affecting 94 workers at the Columbiana plant. The decision is based on "market conditions," according to Grede's CEO. Jun 30, 2020. Grede Holding LLC confirmed a local news report of its plan to close the foundry in Columbiana, AL. SHAKEOUT | FOUNDRY MANAGEMENT & TECHNOLOGY Foundry's 2019-2020 Where-to-Buy Directory. Oct 29, 2019. The Foundry Management & Technology Where-To-Buy Directory is designed to help foundries and diecasters locate suppliers for all of their metalcasting needs and purchasing decisions -- quickly and conveniently. Materials. CANEKAST ACQUIRES MORE ALUMINUM CASTING CAPACITY Circular economy, set to be the biggest revolution in the global economy in 250 years according to Accenture, is part of the ongoing narrative on industrial sustainability, which aims to increase the reuse of resources and minimize the generation of waste. Recent economic factors such as input cost rises and resource volatility have heavily influenced this shift toward a circular approach, but IMPREGNATION OF LARGE CASTINGS Impregnation of large castings include machine bases for various production lines and molds used to make thermoset plastic parts. For further information, contact IMPCO, Tel 401-521-2490; Fax 401-521-5690. mail@impco-inc.com. Or, visit www.impco-inc.com. FOR INVESTMENT CASTERS, FOAM PATTERNS For Investment Casters, Foam Patterns. These artificial hip-joint castings are made using a foam pattern known as FoPat, which makes it possible to produce castings with no pattern-removal step, eliminating the use of steaming to remove wax patterns. A shroud segment showing wax (bottom) and FoPat (top) patterns. TOP 10 WAYS TO MAXIMIZE CRUCIBLE SERVICE LIFE 7. Every crucible has a maximum temperature limit. If you exceed that limit the crucible will be damaged and may fail. Keep close control of crucible temperatures. Allowing molten metal to solidify in the crucible also may damage the crucible when that metal is reheated for pouring. 6. Avoid physical damage by charging correctly and carefully. 6 REASONS WHY “SMART” GOAL-SETTING DOES NOT WORK You’re probably familiar with the concept of Smart goals. “Smart” is an acronym for ideas, tactics, or methods that are developed to be 1) specific, 2) measurable, 3) achievable, 4) realistic, and 5) time-bound. Organizations use Smart goals for two reasons. When addressing each aspect identified by the acronym, the anticipated result is REAL-TIME LASER-BASED MOLTEN-METAL MONITORING Real-Time Laser-based Molten-Metal Monitoring. New spectrometry method combines advances in refractory manufacturing and laser metrology to read chemical and temperature changes, without stopping production. All the fortunes of metalcasting companies depend on a series of thermal and chemical reactions that are not quite as predictable asthe
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