|
Metal Casting Foundry Solutions
Coldwell-Wilcox Technologies steel foundry manufactures precision gray and ductile iron green sand castings. Finished metal castings have been produced from CAD drawings in as little as 4 days. Carefully selected raw materials produce a superior metallurgy, saving up to 20% in roughing and finish machining time. A just-in-time strategy has been implemented to reduce costs, lead times, work-in-process and inventory. Coldwell-Wilcox'spartner Cas-Fab, has ISO 9001:2000 experience for the Plastics, Machine Tool, Paper, Printing, Elevator, Construction, Turbine, Air Compressor, Pump, Valve and Refrigeration industries.
Metal Casting Foundry Facility Capabilities
Total Capacity -
3,500 Tons/Month
Weight Range -
5 to 80,000 pounds
Material Specifications
Gray Iron...............Class 30 to Class 50
Ductile Iron..........60-40-18 to 120-90-02
Specializing in jobbing and semi-production order quantities
Plant Size
274,000 Square Feet
Foundry Employees
249.... Production
37..... Supervisory, Engineering, Quality Control, Production Control,
Pattern Shop, Maintenance
286…. Total
MOLDING
LARGE CASTINGS |
No-bake, Large Flask and Pit Molding |
Mold Size: |
74" x 65" x 7"/7" to 144" x 144" x 48"/48" |
Weight Range: |
4,000 to 80,000 pounds |
MEDIUM CASTINGS |
No-bake, Semi-Automatic Line for Flaskless Molds |
Mold Size: |
27" X 27" x 10"/10" to 84" x 72" x 27"/27" |
Weight Range: |
300 to 4,000 pounds |
SMALL/MEDIUM CASTINGS |
Green Sand Cope & Drag Molding Line |
Mold Size: |
30" X 42 " X 14"/14" |
Weight Range: |
35 to 300 pounds |
CLEANING & PAINTING
47,600 square feet of modern cleaning facilities, including: |
LARGE CASTINGS |
|
1. Abrasive Cleaning, Pangborn #513 type MRS Rotoblast Rooms, with both: |
|
|
50,000 pound capacity car |
|
|
8' diameter table with 10' work circle, 70,000 pound capacity |
|
MEDIUM CASTINGS |
|
1. 96" Wheelabrator, Single Arm, tray lift off Table Blast |
|
2. Integrated Cleaning Booths |
|
|
4 - Enclosed booths with crane and lift table capacity to 4,000 pounds |
|
SMALL CASTINGS |
|
1. A 27 cubic foot Wheelabrator Tumble Blast and Reclamation System with 460 shot blast |
|
2. Integrated Cleaning Booths |
|
|
2 - Swing Frame Booths, 300 pound capacity |
|
|
3 - Snag Grinders, 1 - 65 pound capacity |
|
SPECIAL OPERATIONS AVAILABLE |
We offer prime, finish and special finish paint, high temperature anneal, stress-relief, complete hydrostatic testing, ultrasonic and other non-destructive testing methods, paint operation, and outside x-ray services. |
|
MELTING
Gray and ductile iron grades are controlled to the appropriate ASTM, DIN, or equivalent designation by charge make-up, chemical analysis, chill wedge testing, and temperature checks verified at the spout before pouring and at the ladle after treatment. Chemical analysis consists of cooling curve carbon equivalent determinations, combustion method of total carbon and sulfur analysis, and spectrographic analysis of up to 28 elements. Separately-cast, cast-on, or trepanned tensile specimens are used to qualify the mechanical properties.
Customer requirements for chemical or mechanical property specifications not covered in the preceding ASTM designations require specific purchase documentation and can be produced with special manufacturing and certification practice.
Brinell Hardness ranges on castings may be specified with prior agreement as to location of testing.
Computer-calculated gating, risering, and solidification modeling helps to insure reliability in all metal sections.
-
One (1) 4200KW Line Frequency, 60 Hertz, 15-Ton Holding Capacity, Coreless Induction Furnace.
-
Two (2) 3600 KW Medium Frequency, 200 Hertz, 10-Ton Holding Capacity, Coreless Induction Furnaces.
-
Charging Equipment: Inductotherm 24-Ton Per Hour (Eight 6,000 Pound Charge Batches), 60' Balanced and Isolated Vibratory Transfer Conveyor. 10,000,000 BTU Per Hour Scrap Dryer with 20,000,000 BTU Capacity. 12,000 Pound Capacity Traversing/Pivot Conveyor and Car.
|
|
MATERIAL CHARACTERISTICS OF DUCTILE IRON
PRODUCED BY CAST-FAB TECHNOLOGIES, INC.
AS COMPARED TO ASTM A-874, DIN 1693,
AND ASTM A-36 STRUCTURAL STEEL
|
TENSILE
STRENGTH |
YIELD
STRENGTH |
PERCENT
ELONGATION |
|
English |
Metric |
English |
Metric |
|
ASTM
A-874 |
45,000 |
(315) |
30,000 |
(210) |
12.0% |
DIN 1693
Part I |
58,000 |
(400) |
38,000 |
(250) |
15.0% |
ASTM
A-36 |
58,000 |
(400) |
36,000 |
(250) |
20.0% |
CFT
Average |
60,100 |
(402) |
38,400 |
(266) |
23.1% |
METAL SPECIFICATIONS
GRAY IRON CLASSIFICATIONS |
Mechanical Properties |
Type |
Class
30 |
Class
35 |
Class
40 |
Class
45 |
Class
50 |
Minimum Tensile |
- |
- |
- |
- |
- |
Strength (PSI)* |
30,000 |
35,000 |
40,000 |
45,000 |
50,000 |
Brinell Hardness* |
170-241 |
187-241 |
187-255 |
196-255 |
196-269 |
Suggested Minimum
Wall Thickness |
3/16" |
3/8" |
1/2" |
5/8" |
3/4" |
Chemicals (Typicals) |
Type |
Class
30 |
Class
35 |
Class
40 |
Class
45 |
Class
50 |
Silicon |
2.00 |
1.70 |
1.50 |
1.45 |
1.40 |
Manganese |
0.65 |
.070 |
0.80 |
0.90 |
0.90 |
Phosphorus (Max) |
.08 |
.08 |
.08 |
.08 |
.08 |
Sulfur (Max) |
.12 |
.12 |
.12 |
.12 |
.12 |
Total Carbon |
3.50 |
3.40 |
3.20 |
3.10 |
3.00 |
Chromium |
- |
- |
- |
- |
.35 |
Molybdenum |
- |
- |
- |
- |
.30 |
* On a 1.2" ASTM A-48B Test Bar |
DUCTILE IRON CLASSIFICATIONS |
Type |
60-40-18 |
65-45-12 |
80-55-06 |
100-70-03 |
Minimum Tensile
Strength (PSI) |
60,000 |
65,000 |
80,000 |
100,000 |
Minimum Yield
Strength (PSI) |
40,000 |
45,000 |
55,000 |
70,000 |
Minimum Elongation
in 2" |
18% |
12% |
6% |
3% |
BHN (Typical) |
143-187 |
156-217 |
187-255 |
240-302 |
Note: Mechanical properties determined from a machined .505 diameter test bar cut from an ASTM 3" "Y Block" or a "Modified Keel Block Bar". |
|
