(This week's post is from Alcast Technologies's video of the aluminum green sand foundry metalcasting process.)
"Alcast Technologies uses only the best automated molding technologies available to produce the industry's highest quality green sand molds while maintaining unparalleled productivity standards. Two state of the art Roberts Sinto FBO series Flaskless Molding Machines are used to produce molds within a 16" x 20" frame and a 20" x 24" frame. These investments have significantly improved mold design flexibility and give Alcast a distinct advantage over more rigid and antiquated automated technologies."
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Meet them and The Hill and Griffith Company Booth 739 at the Precast Show in Louisville, Ky Tomorrow Feb. 28 thru March 2, 2019
EJ recently completed a video of one of their new facilities. It's a very modern, high-performance high-pressure green sand foundry. Watch the video here.
From the press release, "The legacy continues. During our 135th anniversary of doing business, we are proud to open a new state-of-the-art greenfield foundry. This new manufacturing operation allows EJ to remain competitive, grow the business, and retain our talented employees. The new facility is situated on a 200-acre site, just 14 miles from the original foundry. It features four electric melt furnaces, two molding lines, and state-of-the-art automation and technology. Much of the new facility is operational, with the installation of the second molding line expected by April, 2019.
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Precast Show
Lightweighting isn’t new to the auto industry, but it’s finally mature enough to make a significant impact on manufacturers, drivers and the whole planet.
John Hitch | Dec 10, 2018 | INDUSTRY WEEK
Even if you’re not a car aficionado, you can see why the Chevy Corvette C2 — aka the Stingray — is revered among the pantheon of American automotive manufacturing. Sleek. Classy. And fast. Really, really fast. It’s everything a muscle car should be. But what you can’t immediately see is how innovative and ahead of its time it was at its 1953 release.
Chevy made the Corvette body from fiberglass rather than steel—and the difference shows on the stopwatch. A 1967 model with a 427 engine could accelerate from 0 to 60 in 4.7 seconds. This has a lot to do with the V8 engine, but the lightweight design provides that extra performance edge. It’s basic physics: Lighter vehicles require less power to move them faster. For Chevy, and any other automaker, it’s also basic economics.
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Regular sand tests performed at Grede-St. Cloud helped identify variations and reduce their causes to achieve better operation.
Green sand control best practices in a metalcasting facility relies on reducing the variation in key measurable aspects of sand properties. All metalcasting facilities make good sand at times and bad sand at times. Successful plants make good sand most of the time.
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(This week's post is from American Foundry Society's Technical Department's Casting 101)
More than 60% of castings are made using the green sand metalcasting foundry molding process, but what is that? Green sand is a mixture of sand or aggregate, clay and water. In a green sand system, the clay and water combine to form a clay bridge that binds sand grains to one another. This bonding mechanism is a hydrated system that requires water, energy, time and technical expertise.
Two types of bentonite clay are typically used: calcium bentonite and sodium bentonite.
Sodium Bentonite (also known as Western Bentonite): Western bentonite is known for its ability to absorb and hold large amounts of water and for the resulting qualities of its high swell (bigger increase in volume) and high viscosity. It is good for green sand mixtures requiring high dry strength and hot strength, such as for iron and steel casting. It is more difficult to mull and help the clay to attach to the sand grains, so more mull energy is required.
This sodium-based clay is capable of swelling approximately 15 times its dry volume. In molding sand, it helps molding maintain its dimensional accuracy and provides a greater dry/hot strength.
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Non-wetting Insulating Coating for Green Sand and all Metalcasting applications
DESCRIPTION:
When applied as a coating to ladles, runners, metalworking tools, pyrometer tubes, etc. POT AND LADLE COATING acts as a non-wetting insulating coating allowing liquid metal to roll off. This prevents tool attack by liquid metal and extends the life of the coated articles. It works well with zinc, lead, aluminum, and copper-base alloys.
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Sodium Silicate Binders,
Metalcasting Congress
(This week's post comes from the American Foundry Society (AFS) Institute. Learn more by going to the video.)
Published on March 2017
In this 16 minute video-cast, AFS Institute Director of Education Shelly Dutler shares the latest course information and updates from the Institute, including:
March AFS Classroom Courses
- Copper 101
- Copper 201
- Green Sand Molding 101
- Nobake Molding & Coremaking 201
- Casting Cost Estimating
- Permanent Mold Thermal Management
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Metalcasting Congress
(This week's post is a review of FOUNDRY MANAGEMENT AND TECHNOLOGY Magazines' 2017 Metalcasting Outlook. You need to register to read the full report, "2017 Metalcasting Outlook.")
A complex industry like metalcasting never matches overall business trends. It has its own operating rules, its own advantages, and its own vulnerabilities that confound the perspective of finance-based analysis.
Each year, during September and October, FM&T surveys metalcasters to measure the outlook of men and women responsible North America’s foundries and diecasting plants. We seek to identify the problems they face in their businesses and the economy, to learn what plans they're making for the coming business cycle, and to understand better they're expectations for the year ahead.
We surveyed readers by email over a period of six weeks, with a detailed study that focuses on the metalcasting business, its risks and prospects, and the internal and external factors shaping its progress. Their perspective — presented here — is valuable not only because of their insights and advantages, but because they occupy positions that are critical to the prospects of so many other elements of the global industrial economy.
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GREEN HORNET Core Paste,
Metalcasting Congress
Green Hornet™ Core Paste for Green Sand and all core uses in metalcasting foundries
Hill and Griffith GREEN HORNET Core Paste is formulated with organic and inorganic binders, fillers, suspension agents and water. GREEN HORNET™ Core Paste provides good strength in relatively short periods of time and exhibits excellent storage life.
Features
- Good Strength
- Easy Application
- Easy Clean Up
- Excellent Stability
- Low Cost
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Green Sand Casting Products,
Green Sand Foundry Supply,
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Foundry Supply,
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GREEN HORNET Core Paste,
Metalcasting Congress
(This week's post comes from the American Foundry Society (AFS) Institute. Learn more by going to the video.)
Published on Jan 26, 2017
In this half-hour video-cast, AFS Institute Director of Education Shelly Dutler shares the latest course information and updates from the Institute, including:
One of the most popular parts of the course was the water modeling. Clear PVC pipe is used to simulate riser designs and the application of water flow illustrates design principals.
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Green Sand Casting Products,
Green Sand Foundry Supply,
Core Pastes,
Foundry Supply,
Green Sand Release Agents,
Foundry Supplies,
Pattern Release Agent,
Sodium Silicate Binders,
Metalcasting Congress
