Ermak Foundry & Machining, Inc.

creatureworks — Fri, 11 Feb 2022 15:13:57 +0000

CaneKast, Inc. Announces Acquisition of Cushman Foundry

CHASKA, MN (January 28th, 2022) �?Cushman Foundry of Blue Ash, Ohio, was acquired by CaneKast, a leader in non-ferrous foundries. “This transaction enables us to take advantage of opportunities for growth and innovation across our facilities,�?remarked Reg Zeller, CEO and owner of CaneKast. “The addition of Cushman provides us with a strategic location within our network and a knowledgeable workforce that can leverage cutting-edge equipment. We started acquiring foundries five years ago because we believe in local manufacturing. We want to continue to create jobs and opportunities for workers while giving customers a high-value, superior solution.�?/p>

Cushman Foundry’s history stretches back over 30 years as an independent producer of high-quality aluminum castings for many industries, including the fire suppression, industrial fan, and control markets. Before that, Cushman Foundry was a captive facility for one of the current company’s largest customers. “We continue to innovate and expand our existing operations, so when we first started chatting with Rich (Beyersdorfer, prior owner of Cushman), we knew this would be a perfect fit for our organization,�?said Josh Schultz, President of CaneKast. “Now we can combine our expertise and capital with the talent at Cushman to greatly increase their quality and capacity.�?/p>CaneKast’s innovative processes and technology allow Cushman’s clients to access a broader range of services, including brass/bronze/zinc castings, automated molding, heat treat, machining, permanent mold/gravity-fed die-cast, rapid prototyping and enhanced part development.

Eric Sloan, Director of Operations at CaneKast, said, “Our experience improving processes and equipment in our other facilities will be the same playbook we bring to Cushman to ensure their future growth and stability. We have million-dollar capital improvement projects identified that are funded. With this latest acquisition, over 60% of our target customers are within a five-hour drive of one of our factories. Adding Cushman to the mix, we have further secured our companies�?futures and ensured their customers have a partner that is around to grow with them for the long term. As we continue to grow organically and through acquisitions, we are hyper-focused on providing excellent customer service and products.�?/p>

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Ermak Foundry & Machining, Inc.

creatureworks — Thu, 22 Jul 2021 16:02:00 +0000

Casting Source’s 2021 July/August, Q&A article, “You Don’t Have To Be Monet,�?by Kim Phelan, features Reg Zeller.

Casting Source: You’re passionate about bringing manufacturing back to America, and certainly the reasons are many to do so. But is it one of those things that’s easier said than done?

Reg Zeller: I can’t tell you how many times I’ve had this conversation with customers. Bringing something back to the U.S. is substantially easier than what it takes to initially get something going overseas.

We created our own proprietary development process to make this simple. We’ve continued to refine the process so we know all the questions to ask; we have a checklist that we go through and it’s completely transparent to the casting buyers. We just make sure everything is taken care of and we walk them through it.

Tell Us About Your Reshoring Challenges

What parts have you on-shored and what challenges have you faced with switching production facilities? Check our our blog post, Reshore-Broken Supply Chains to learn more, reach out to our experts at ERMAK for free quotes and advice, Info@darolls.net or call 952-448-2801.

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Ermak Foundry & Machining, Inc.

creatureworks — Tue, 22 Jun 2021 16:35:15 +0000

Benefits of Aluminum Prototype Casting

Designers/engineers can gain tangible proof of the component’s quality, find unexpected flaws and perform testing that delivers invaluable data.
Marketers can use prototypes to gain feedback from customers or investors before full-scale production begins.
Designers/engineers can make parts in a wide range of sizes and surface details with various finishes.
Designers can cast unique artistic or decorative sculptures, products, or objects.
Casting is often the cheapest and most direct way of producing a prototype.
Easily produce complex shapes.
Cast almost any sort of product.
Produce almost any size of casting.
Reduce a product’s development timeline.
Allow for functional and product performance testing.
Allow for low-volume, short-run production without the need for expensive tooling.
Reduce development costs to improve return on investment.
Create a wide range of products or custom accessories.

The Fundamentals of Prototype Casting

A prototype is a first model of an object that may be used to generate or duplicate further forms. Mold casting is one of the techniques used by engineers and manufacturing professionals to create prototypes.

Casting is a manufacturing method in which a liquid substance is poured into a mold with a holed-out negative impression of the required shape and subsequently solidified. The solidified part, called a casting, is discharged/broken out of the mold to complete the process.

The Basics of Casting

Melt the metal
Pour metal into a mold that has already been created and conforms to the shape of the intended component
Allow the molten metal in the mold to cool and solidify
Remove the hardened piece from the mold, clean, and, if necessary, apply further finishing and treatment

3D Modeling

3D modeling is an alternative to prototype casting. 3D modeling is a process that produces a three-dimensional physical object from a digital printer by laying down many successive thin layers of material. Although 3D modeling appears to have infinite potential, it does have some restrictions.The layers of material in a 3D print are constructed on top of one other but not fully fused, resulting in a prototype that closely but may not perfectly reflect the object’s real strength and shape. Limited mediums, differing accuracy, manufacturing constraints, size and durability difficulties are all issues that the 3D printing process may face depending on the part and material used.There is an alternative to 3D modeling/casting where an ABS/PLA-type material is printed and then used in place of a pattern. The process has some limitations when hollowed-out shapes are required, but for some applications it creates a fast and inexpensive method to get a part.

3D Printed Sand Patterns

3D sand printers are similar to the 3D printed models, except they print the negative impression of the part. We work with third party partners who 3D print sand patterns for us, similar to the way production sand patterns work. Once the CAD file is adapted for shrink and draft, we typically get these patterns in-house in a few weeks and parts poured in as little as a few days (minus any secondary finishing required). Normally, this process will cost $250-1000/part depending on the size/complexity and it will be �?9%�?of a final part, nearly identical to what we will create during production.

Create Part from Sample

Some customers don’t have a 3D CAD file, they only have a sample of a part or a simple sketch. At this point, we are able to either create a part directly from the sample (say of an old car part) that will be ~1-2% smaller than the original part or we can create a 3D CAD file that the customer approves. The 3D file can be from scratch or by completing a 3D scan of the part �?whatever is needed we are able to take care of it. From this CAD file, we can then run through the any of the processes outlined above.

Share your experiences on prototyping or reach out to us for how we can help develop your first part! Free quotes and advice at info@darolls.net or (952) 448-2801.

More About Prototypes

ERMAK—for ALL of your aluminum casting and machining needs.

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Ermak Foundry & Machining, Inc.

creatureworks — Thu, 03 Jun 2021 16:09:17 +0000

Knowledge of casting defects and what causes them is an essential part of managing casting quality. High-quality foundries avoid pitfalls that cause casting defects.Casting defects in a finished product can occur due to defective pattern design, improper melting of metal, defective molding material, or improper venting. Defects can also occur due to control limitations or human interference.Quality foundries use inspection methods, often radiographic or ultrasonic, to ensure your finished product is defect-free. Ermak Foundry & Machining not only maintains rigorous inspection standards but has the expert staff and high-end equipment to ensure your casting quality is second to none.

Curious about what a great casting can do for your application? Get in touch with us today!

CASTING DEFECTS RELATED TO GAS POROSITY
When a metal retains gas during casting—most often, nitrogen, oxygen, or hydrogen gas—porosity results. Bubbles occur as the casting cools and solidifies because the solid version of the metal cannot store as much gas as the liquid form. These bubbles show on a casting as rounded cavities or holes.

Pinholes �?/span> Pinholes are tiny gas holes (about 2 mm) either at the surface or just below the surface, usually found in the cope (upper) part of the mold, in poorly vented pockets. Pinholes are more or less uniformly dispersed over the surface and occur in large numbers.

Blows –�?/span>blowholes or gas holes are larger cavities than pinholes produced by gases that displace a molten metal’s form. Excessive gas content in the metal bath and the rejection of dissolved gases during solidification create holes between growing crystals. A subsurface blowhole usually isn’t visible until after machining and can require harmonic, ultrasonic, magnetic, or x-ray analysis. Open blowholes are blowholes that appear on the surface of the cast.

Scars �?Caused by improper permeability or venting, a scar is a shallow blow. It typically occurs on a flat surface.

Blisters �?A blister is a shallow blow like a scar, but with a thin layer of metal covering it.

ADDITIONAL COMMON CASTING DEFECTS & CAUSES

Scab �?/span> This flaw arises in sand casting when a part of the mold’s face breaks down, and metal fills the resulting cavity. When metal pours into the cavity, the gas may disengage with enough force to break up the sand. The sand washes away, leaving the space filled with metal.

Core Shift �?A core shift is a defect due to the buoyancy of molten metal that causes the core of the cast to move from its correct position.

Mold Shift �?A mold shift is caused by the mold cope itself shifting sideways relative to the drag. This shift results in a step or indent in the final cast at the parting line.

Drop �?/span> A drop is an unevenly formed protrusion on a casting’s surface. The mold sand breaks away due to insufficient packing, poor molding sand strength, faulty molding equipment, or strong jolts and impacts at the flask during mold assembly, creating this problem. Loose sand that falls into the cavity will also result in a dirty casting surface, either on top or bottom of the casting.

Metal Penetration �?/span> Penetration is a crust of fused sand on the surface of a casting. Some metal will flow between the sand particles for a distance into the mold wall and solidify if sand packing is inadequate. The metal lump will remain attached after removing the cast.

Rat tail �?Rat tails and buckles are irregular lines or cracks on the casting surface. A rat tail is a long, shallow, angular depression in the surface and resembles a buckle, except it’s not shaped like a broad vee.

Buckle �?/span> Buckles are a more severe form of a rat tail. A buckle is a long, broad, shallow depression that occurs in the surface of flat castings. It extends in a straight line across the entire flat surface.

Wash �?/span> A wash or cut is a low projection on the drag face of a casting that extends along the surface, decreasing in height as it extends from one side of the casting to the other end.

Hot Tears �?/span> Hot tears/cracks appear as irregular crevices with a dark oxidized fracture surface. They arise when the solidifying metal does not have sufficient strength to resist tensile forces produced during solidification.

Shrinkage �?/span> A shrinkage cavity is a depression in a casting resulting from the volume contraction during solidification.

Swell �?/span> A slight, smooth bulge usually found on vertical faces of castings resulting from liquid metal pressure. It might be owing to the mold’s insufficient strength, possibly caused by a high water content or a lack of ramming.

Core Shift Defect in Casting

Buckle Casting Defect

Molten Aluminum Over Flow

ERMAK—for ALL of your aluminum casting and machining needs.

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Ermak Foundry & Machining, Inc.

creatureworks — Tue, 01 Jun 2021 23:03:39 +0000

Five non-ferrous metal applications which affected global industries in a big way include aluminum aircraft frames, magnesium transmissions, titanium golf clubs, zinc electrical hardware, and bronze gears.

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The Industrial and Transportation Revolutions fueled the demand for non-ferrous metal applications.

The development of the airplane industry, the commercialization of automobiles, and the mass production of durable and recreational consumer goods paved the way for today’s real-world applications of non-ferrous metals that provide technological advantages at indispensable cost savings.

ALUMINUM AIRCRAFT

Lightweight, durable, strong, and highly flexible, aluminum has proven to be the best material for constructing aircraft.

No industry has benefited more from aluminum than the airline industry. Aluminum parts have been used in aircraft construction since the Wright Brothers used an aluminum crankcase for the WrightFlyer.

By weight, 80% of all aircraft consist of aluminum parts. The fuselage, wings, rudder, doors and floors, frames of seats, fuel nozzles, hydraulic systems, ball bearings and engine turbines are all made of aluminum.

Aluminum alloy development/production and advances in aircraft technology are tightly connected. Aluminum casting technology reduces manufacturing costs while also allowing engineers to incorporate creative designs and concepts.

MAGNESIUM TRANSMISSIONS

Magnesium cast parts offer a lightweight component and feature integration proven to be durable and highly effective.

The advantages of using transmission parts made from magnesium in automobiles, trucks, and other vehicles are of no surprise. Magnesium cast parts are the choice of the industry because the metal is 75% lighter than steel and 33% lighter than aluminum, has a high strength to weight ratio and high impact resistance, has excellent dimensional stability, and can be cast to just about any shape.

Of all the most popular metal alloys, magnesium has the lowest density, making it an attractive fit in the manufacturing of transmission parts. It not only reduces the total mass of a vehicle but its weight distribution and balance. Lowering the front end improves the dynamics of the vehicle.

The application of magnesium cast alloys is also compatible with commercial automatic transmission fluids. In laboratory studies, the effects of high temperature, the presence of condensation or water, and the galvanic coupling with steel caused no significant corrosion of magnesium under any of the test conditions.

TITANIUM GOLF CLUBS

Titanium is the strongest and most durable of metals and impervious to the elements and weather conditions.

Reverend William Gregor, English pastor, mineralogist, and chemist, first discovered titanium ore in 1791. He had no idea that 200 years later it would transform the game of golf by creating the best golf clubs ever made. In the 1970s, club designers realized titanium is an amazingly strong yet lightweight metal�?5% lighter than steel. It took another twenty years to perfect the design before the club’s widespread use took off in the 1990s.

Titanium’s lightweight material allows for a more prominent sweet spot on the clubhead, resulting in a faster swing, and optimizing the ball’s launch, flight, and trajectory. The distance a ball travels increased by 20 percent on average.

The introduction of titanium in the making of golf clubs, with its advantage in durability and longevity and increasing the distance part of the game, has effectively revolutionized the sport.

ZINC-BASED ELECTRICAL HARDWARE

Zinc is one of the strongest and toughest metals there is for casting parts. Zinc creates a formidable barrier in protecting metal surfaces.

The relentless forces of corrosion and chemical leaks on wire terminal connections in industrial environments increase the risk of electrical failure. Industry experts have indicated that faulty connections cause up to 60 percent of electrical downtime.

Zinc casting and electroplating in the manufacturing of electrical components and parts have proven to be the most effective applications in combating the effects of corrosion and chemicals in harsh industrial environments. Zinc is a hard metal, dimensionally stable and self-lubricating, and its properties make it ideal for electrical and thermal conductivity.

It’s an abundant, low-cost raw material and pouring happens at a moderate temperature, making it energy efficient. Today, it is used extensively in the manufacturing of electrical hardware.

BRONZE GEARS

Bronze is a copper-based alloy. Adding other metals, typically tin creates a significantly harder alloy than copper alone.

A wide range of gear-drive systems, power transmission systems, jack screws, landing gears, and pumps all use bronze-cast gears. A variety of sectors, including automotive, aviation, machine tooling, marine, and oil production, utilize bronze gears.

Bronze has specific characteristics that help it to last longer. Compared to other ferrous and nonferrous metals, such as steel or aluminum, bronze has a low friction coefficient and excellent load-bearing qualities. Lower friction equals better efficiency and less wear, making bronze a superb choice.

Other factors that make bronze gears a good bearing material are corrosion resistance, resistance to high temperatures, and good wearing behavior. In addition, bronze is easily machined, welded, brazed, and soldered.

Ermak, through its sister company Patriot Foundry offers cutting-edge Bronze Sand Casting Services. Using tried-and-true methods that cut down on production costs while maintaining product quality, Ermak/Patriot provides you with comprehensive bronze casting services.

ERMAK—for ALL of your aluminum casting and machining needs.

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Ermak Foundry & Machining, Inc.

creatureworks — Fri, 21 May 2021 02:51:04 +0000

“Superior is a great fit to help us achieve our vision.”

CHASKA, Minnesota, May 20, 2021 �?CaneKast and its companies Ermak Foundry & Machining, Patriot Foundry & Castings and RDS Dock Hardware have acquired Superior Aluminum Castings of Independence, Missouri. Reg Zeller, CEO and owner commented, “Four years ago we started acquiring non-ferrous foundries because we believe in local manufacturing. We are building a network of facilities that will provide the benefits of a small business yet have state-of-the-art technology typically only found in large conglomerates. Superior is a great fit to help us achieve this vision.�?/p>

Superior’s history stretches back nearly 75 years.

Superior’s history stretches back nearly 75 years. Seth Cutler, President of the companies, said, “We are leveraging Superior’s advanced equipment and expertise pouring aluminum alloys to provide our customers further diversification across facilities. We plan to hire additional employees and start a large-scale training program across our group and update the back-office systems to boost production.�?/p>

Superior serves customers in the metrology, aftermarket automotive, and sensing markets.

Ermak serves a wide range of light- to medium-duty manufacturing industries; Patriot customers include the Department of Defense, aerospace, biotech, and electronics industries. Superior adds customers in the metrology, aftermarket automotive, and sensing markets. Seth said, “Being our fifth acquisition, we have a good understanding of how to quickly integrate the new enterprise, utilizing the best practices from the old and new businesses to make all of them better.�?/p>

CaneKast will grow its network and expand into new markets.

Under the expertise of Superior’s former owner, David Barnhard, CaneKast will grow its regional and national network and expand into new markets. Superior’s customers will have access to additional capacity, heat treat, machining, permanent mold/gravity-fed die-cast, and rapid prototyping and improved part development through Ermak’s proprietary product development process.

We are hyper-focused on providing excellent customer service

Eric Sloan, GM, said, “Our access to capital and experience adding automation across the enterprise provides building blocks for the future growth of Superior. We have a strong foundation from which to scale the companies; nearly 50% of our target customers across the US/Canada are within a five-hour drive of one of our foundries. Adding Superior to the mix, we have further secured our companies�?future, having nearly quintupled in four years. As we continue to grow organically and through acquisitions, we are hyper-focused on providing excellent customer service and products, ensuring our growth supports our values.�?/p>

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Ermak Foundry & Machining, Inc.

creatureworks — Wed, 21 Apr 2021 21:29:04 +0000

Metal Solidification is the comprehensive transformation process of a liquid into a solid and the basis of casting technology, including melting, pouring, and re-solidating a metal or metal alloy within a mold to produce a final desired product.

1. Melting

The casting process starts by heating a metal alloy in a crucible until it melts. Heated metal becomes liquid when it reaches its melting point. The melting point of metal depends upon the type of metal or alloy. For instance, zinc alloys melt around 900 degrees F, whereas some of the bronze alloys melt above 2000 degrees F. Pure metals melt at the same constant temperature. Conversely, metal alloys will melt within a range of temperatures depending on the composition of the materials. In its molten state, a metal contains a high amount of energy. The alloy, heated above its melting point, allows enough time for the metal to be poured into the mold before it cools.

2. Degassing & Modification

Before pouring, zinc alloys and aluminum alloys need to be degassed. Degassing is accomplished by inserting a graphite lance into the melt. The lance spins very fast, and then argon or nitrogen is injected through the lance, dispersing it through the melted alloy. The argon or nitrogen moves dissolved hydrogen and other contaminants to the surface of the melt. We then remove this contamination from the surface before we pour the alloy into the mold.Many alloys require modification before pouring. These modifications increase metal flowability, improve grain structure, remove contaminants, etc. Some of the materials we use to accomplish this are titanium-boron, copper-phosphorous, strontium, manganese, etc.

3. Pouring

After degassing and modification, we test the metal temperature to ensure it is approximately 50-150 degrees Fahrenheit above its desired pouring temperature. The extra 50-150 degrees will allow enough time for the metal to flow throughout the part before solidifying during the pouring process. We transport the crucible or ladle to the pouring lines and pour the liquid metal into readied molds. The hollow cavity of the mold is the shape of the desired end product. Sometimes this cavity is one part, and sometimes, it is several individual parts. It is imperative to keep the crucible lip as close to the sand mold as possible to reduce the velocity of the metal as it enters the mold cavity.

4. Freezing

Once the molten liquid is poured into the mold, it cools rapidly. When the temperature of the liquid metal changes below the melting point of that particular metal or alloy, the solidification process begins. The freezing process usually takes less than a few minutes.

5. Solidification

As the temperature drops further, the molten metal loses energy, and crystals begin to form. This process starts near the mold walls, where it cools first. These crystals eventually become grains within the final structure. If the metal solidifies slowly, the grains are longer. If it cools quickly, the grains are visibly shorter. The crystals (or dendrites) continue to form and harden until the entire melt solidifies.During the solidification process, the metal is shrinking. Shrinkage occurs because most metals are less dense as a liquid than a solid. Shrinkage can create a void at the last point to solidify. Avoiding shrinkage defects can be accomplished by the use of risers and other techniques. Risers, also known as feeders, are reservoirs built into a metal casting mold that will help prevent cavities in the casting.

6. Casting

Once hardened, the cooled metal product is removed or shaken loose from the sand mold to complete the solidification process. The finished piece is called a casting.

Although different casting methods employ various equipment and techniques, all observe the metal solidification process. It takes an experienced and skilled foundry to control this process and avoid casting defects that result from improper handling of the solidification process.

Casting Services

Contact Ermak to learn more about our comprehensive non-ferrous foundry services like sand casting, precision casting, aluminum casting, and permanent mold casting.

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creatureworks — Wed, 14 Apr 2021 15:33:00 +0000

Metal casting is when molten metal is poured into a mold and allowed to solidify into an object. The object that solidifies is called a casting.Sand casting is the most widely used metal casting process in manufacturing, and almost all casting metals can be sand cast. Sand casting is pouring molten metal into a sand mold; the metal then solidifies to fill the shape of the mold. A few examples of everyday items manufactured by the sand casting processes are gears, dies used in the packing industry, sports and recreation equipment, cylinder heads, pump housings, and valves.While proper equipment and experience are required to produce a casting free of defects, the sand casting process itself is pretty simple.

Precision Sand Casting Process in Six Steps

1. Create The Mold

The first step is to create a mold for the sand casting. Form a sand mold by packing sand into each half of a container that includes a pattern of your desired object. The “pattern” is a replica of the external shape of the desired casting. The top and bottom halves of the container mold are known as the “cope” and “drag.” Remove the pattern. The cavity that will form the casting remains. Learn more about the types of sand used in sand casting.

2. Prepare the Mold

Once the mold has is ready, it must be prepared for the molten metal to be poured. The surface of the mold cavity is first lubricated to help with the removal of the casting. The type of lubricant will depend on the kind of sand and metal used. The mold halves are then closed and securely clamped together. The mold halves must remain securely closed to prevent the loss of any material.

3. Pour Molten Metal into Mold Cavity

Pour molten metal into the mold through the “gating system.” A gating system is a gap leading from the casting cavity to the outside of the mold. You can see “jackets” on these molds that secure the two halves together. This image shows pouring molten aluminum into the mold.

4. Allow Metal to Cool

The molten metal that’s poured into the mold will begin to cool and solidify once it enters the cavity, known as the metal solidification process. The mold is open once the proper cooling time has elapsed.

5. Remove Cast from Mold

After the solidification time has passed, break the sand mold apart and remove the hardened casting. A vibrating machine can shake the sand and casting out of the flask. Once removed, the casting will likely have some sand and oxide layers stuck to the surface. Use shot blasting to remove the remaining sand. Recondition sand for reuse.

6. Trim Excess Metal From Casting

During cooling, the material from the channels in the mold solidifies and attaches itself to the casting. This excess material is trimmed from the casting either manually or using a trimming press. The time required to trim the extra material depends on the size of the casting—larger castings require a longer trimming time. The scrap material that results from the trimming is often reused in the sand casting process.

Finish, polish, powder coat

Depending on the intended use of the final product, the casting may be polished or finished to provide a functional or aesthetic surface for its final application. Surface finishes of varying grades can be applied to remove the roughness left on the casting surface.

Ermak can provide raw castings or castings ready for use. Secondary finishing operations, including powder coating, are additional options. Contact Us and with any questions about the casting process.

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Ermak Foundry & Machining, Inc.

creatureworks — Wed, 31 Mar 2021 20:31:00 +0000

For over a half-century, Ermak has worked to master and perfect the art of sand mold casting. Sand casting is a popular method of producing non-ferrous alloy casts. This process was invented over 6,000 years ago and continues to undergo modernization. There are three types of sand used in casting, green sand, water glass or sodium silicate, and resin sand.Over 70% of the world’s metal castings are produced via the sand-casting process. Sand casting is highly efficient and cost-effective.

Types of Sand Used in Sandcasting

1. Green Sand

Green sand castings are formed using sand molds formed from wet sand that contains water and organic bonding compounds, also known as clay. The term Green Sand refers to the sand mold not being “set” or “green” or “uncured” when the metal is poured into the mold. Because the sand can be reused, sand casting with green sand is easy and inexpensive. The disadvantage is that sand is a soft mold that can collapse or shift during casting.

2. Water Glass or Sodium Silicate

Sodium silicate can be used to create sand mold castings. This process is beneficial in sand casting, where a cavity is required. Sodium Silicate can quickly go from a liquid to a solid by passing carbon dioxide through it. This causes the sodium silicate to dehydrate. Sodium silicate must be mixed with other materials so the core can be removed during product break down. If the mixture isn’t correct, the core will become stuck within the casting.

3. Resin Sand

The molding material for resin sand casting is a blend of quartz sand and resin sand. When resin sand is mixed and heated, it hardens into a solid, smooth mold. A solid mold produces fewer faulty castings, but it comes at a greater cost and a slower production rate. Resin sand molds take longer to make because each one must be mixed and burned individually.

Ready to Make Your Product?

Our family of foundries, Ermak Foundry and Machining, Northwest Casting, and Patriot Foundry & Castings are nationally recognized non-ferrous foundries with decades of sand casting experience. Need help determining which type of sand casting process is best for your project? More About Sand Casting. We are ready to help with every step of the way.Contact Us!

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Ermak Foundry & Machining, Inc.

creatureworks — Fri, 19 Mar 2021 21:09:12 +0000

Alloy Definition

Alloy: verb, past tense: alloyed; past participle: alloyed
mix (metals) to make an alloy.
“alloying tin with copper makes bronze”

What is a Metal Alloy?

An alloy is a mixture of two or more elements with at least one metal that lends its properties to the total compound. An alloy occurs when the properties that happen with the addition cause a change in a property that is beneficial. It is possible to mix two metallic substances and form a mixture of metals that is not an alloy. A metal alloy retains all the metal properties in the resulting combined material; electrical conductivity, tensile strength, ductility, opacity, and luster.

How is an alloy different from a pure metal?

Metal alloys are classified into two types: substitutional alloys, in which one metal replaces another and interstitial alloys, in which one metal fits between the spaces in another metal

Pure Metal
Pure metal elements are metals that have not been alloyed with other metallic elements.

Substitutional Alloys Component atoms are the same size. One metal takes the place of another.

Interstitial Alloys Component atoms are different sizes. One metal fits in-between the spaces in another metal,

Alloys vs Pure Metal

There are many advantages to using alloys vs. pure metals. Pure metal elements are metals that have not been alloyed with other metallic elements. Many pure metals are soft. An alloy tends to be harder/stronger and more durable than pure metal because the mixture has atoms of different sizes. Alloys also provide high strength, resist corrosive environments, and improve appearance, as they are lustrous and contain a better finish.

Common Alloys and their Applications

Most of us encounter alloys in our daily life. Alloys are present in hardware, cars, gears, pistons, silverware, cookware, jewelry, tools and more. We will help you select the best alloy for your product. Below are a few examples of alloys we pour.

A242 Aluminum

Cast aluminum alloy used specifically where strength and durability at extreme high temperatures are called for. Used specifically where strength and durability at extreme high temperatures are called for.

Typical applications

Diesel, aircraft and motorcycle pistons

535 Aluminum/Magnesium

This aluminum/magnesium alloy provides superior corrosion resistance, has excellent machining characteristics, and does not need heat to reach its full properties potential.

Typical applications

Marine Hardware—Check out our line of Marine Hardware

RDS Dock Hardware

C905 Tin/Bronze

A bronze alloy—also referred to as Gun Metal. This alloy is perfect for applications that call for heavy load bearing under slow speeds.

Typical applications

Gears and Seal Rings

C955 Nickel/Aluminum/Bronze

A nickel/aluminum/bronze alloy known for its resistance to impact and shock.

Typical applications

Bushings, Bearings, Gears, Marine Applications, Pump Parts, Machine Tool Parts, Aircraft Parts

C863 Manganese/Bronze

This Manganese Bronze alloy can operate under heavy loads at high speeds. It shows superior mechanical qualities and corrosion resistance.

Typical applications

Bushings, Bearings, Gears, Gibs, Bridge Pins, Valve Stems and Hydraulic Cylinder Parts.

Metal Alloy FAQ

What is an alloy?

An alloy is a mix or solution of at least one metal element and another metal or other element. Alloys include materials such as brass, pewter, bronze, white gold, rose gold and steel.

What are copper alloys?

Copper-based alloys have the metal copper as their principal component. They’re highly resistance to corrosion. The best known copper alloys are bronze and brass. A bronze alloy is copper plus tin. A brass alloy is copper plus zinc. Copper is also added to precious metals like gold and silver resulting in alloys like rose, red, pink and white gold.

Why are alloys used?

Alloys blend the best of the metals and elements they incorporate. Also, alloys can exhibit unique properties—different from the metals they are created from to achieve exceptional properties like hardness, appearance, durability, and other attributes. Products and parts made from alloys that align with the alloy’s strengths are reliable and often are aesthetically and functionally superior.

Advantages of aluminium alloys

Aluminum alloys are common materials of choice for many engineers. Aluminum alloy products and parts are
light, strong, resilient, ductile at low temperatures, corrosion-resistant, non-toxic, heat-conducting, reflective, electrically conducting, non-magnetic, non-sparking, and non-combustible. Some of the more common aluminum alloys that Ermak pours are A356 / 356 / 333 / C355 / 319 / 535 / and 713.

Advantages of zinc alloys

Zinc alloys are extremely strong and used in a variety of industries, including outdoor and marine, as well as medical and automotive. Zinc alloys are lightweight, strong, have long-lasting corrosion protection, and excellent wear resistance. Ermak’s network of foundries pours ZA-12 / ZA-27

Bronze alloys

Bronze alloys are also known as workhorse metals used in a range of industries, from aerospace to marine. Bronze is one of the most versatile and corrosion-resistant alloys known to man. Ermak’s network of foundries pours bronze alloys C862 / C863 / C865 / C876 / C87610 / C89833 / C903 / C905 / C958

Distinction between alloying and impurity

The distinction between alloying and impurity is not always clear; for example, when silicon is added to aluminum, it may be considered an impurity or a valuable component depending on the application. Silicon increases strength while decreasing corrosion resistance.

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Ermak Foundry & Machining, Inc.

Ermak Foundry & Machining, Inc.

Ermak Foundry & Machining, Inc.

Casting Source’s 2021 July/August, Q&A article, “You Don’t Have To Be Monet,�?by Kim Phelan, features Reg Zeller.

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Benefits of Aluminum Prototype Casting

The Fundamentals of Prototype Casting

The Basics of Casting

3D Modeling

3D Printed Sand Patterns

Create Part from Sample

More About Prototypes

ERMAK—for ALL of your aluminum casting and machining needs.

Ermak Foundry & Machining, Inc.

ERMAK—for ALL of your aluminum casting and machining needs.

Ermak Foundry & Machining, Inc.

Five non-ferrous metal applications which affected global industries in a big way include aluminum aircraft frames, magnesium transmissions, titanium golf clubs, zinc electrical hardware, and bronze gears.

The Industrial and Transportation Revolutions fueled the demand for non-ferrous metal applications.

ALUMINUM AIRCRAFT

MAGNESIUM TRANSMISSIONS

TITANIUM GOLF CLUBS

ZINC-BASED ELECTRICAL HARDWARE

BRONZE GEARS

ERMAK—for ALL of your aluminum casting and machining needs.

Ermak Foundry & Machining, Inc.

“Superior is a great fit to help us achieve our vision.”

Superior’s history stretches back nearly 75 years.

Superior serves customers in the metrology, aftermarket automotive, and sensing markets.

CaneKast will grow its network and expand into new markets.

We are hyper-focused on providing excellent customer service

Ermak Foundry & Machining, Inc.

Metal Solidification is the comprehensive transformation process of a liquid into a solid and the basis of casting technology, including melting, pouring, and re-solidating a metal or metal alloy within a mold to produce a final desired product.

1. Melting

2. Degassing & Modification

3. Pouring

4. Freezing

5. Solidification

6. Casting

Casting Services

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Precision Sand Casting Process in Six Steps

1. Create The Mold

2. Prepare the Mold

3. Pour Molten Metal into Mold Cavity

4. Allow Metal to Cool

5. Remove Cast from Mold

6. Trim Excess Metal From Casting

Finish, polish, powder coat

Ermak Foundry & Machining, Inc.

Types of Sand Used in Sandcasting

1. Green Sand

2. Water Glass or Sodium Silicate

3. Resin Sand

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Alloy Definition

What is a Metal Alloy?

How is an alloy different from a pure metal?

Alloys vs Pure Metal

Common Alloys and their Applications

A242 Aluminum

Typical applications

535 Aluminum/Magnesium

Typical applications

C905 Tin/Bronze

Typical applications

C955 Nickel/Aluminum/Bronze

Typical applications

C863 Manganese/Bronze

Typical applications

Metal Alloy FAQ

Casting Source’s 2021 July/August, Q&A article, “You Don’t Have To Be Monet,�?by Kim Phelan, features Reg Zeller.