vertically-speaking, robinson foundry debuts aluminum green sand casting.
Key aluminum auto parts, Robinson added low
Vertical separation of the pressure of the green sand repertoire.
We have been looking for better ways . \"
Chairman of Robinson Foundry
In Alexandria, Alabama, when asked about his foundry pushing high
Separate green sand casting of aluminum.
\"We think we have an untapped market in our hands.
\"The profile of Robinson Foundry begins and ends with Joe Robinson\'s statement. As a medium-sized, single-
Robinson Foundry\'s factory operation Foundry has learned in the eyes of its customers the importance of reinventing itself by entering new, unknown markets.
See for yourself: * 1985--
Become the first foundry to enter the loss foam in large quantities when starting the gray iron facility (
See the sidebar, \"Robinson opens the door to the lost bubble \"). * 1989--
Following the start of its successful black bubble loss-
Bao Ding\'s-Robinson joint-
Venture aluminum foam operation. * 1995--
Became the third independent foundry in North America to pour aluminum through vertically separated green sand casting, and obtained GM\'s first-class supplier status in 1998. * 2000--
Installed the first low in North America.
Pressure vertical shunt sand casting system for aluminum. As a family-
Because there is no precedent to follow, it is often a belief to take risks in new processes and markets.
A review of Robinson casting\'s entry into the new aluminum casting field details the company\'s beliefs and the questions that must be answered to succeed in the unknown waters.
Aluminum green sand casting?
1995, after the loss of the bubble business 【
Quote the company\'s gray iron(Citation Foam)
In 1993 and aluminum Intermet(
Alexander City Foundryin 1995]
Robinson Foundry cast Gray and tough iron on three vertically separated green sand lines.
\"When we sell the foam foundry, we know that we either stay in the foundry industry, live a good life, or find another way to grow the business,\" says Joe Robinson.
\"Our decision was to grow, which led to the aluminum green sand casting.
\"In listening to Joe Robinson and Jerry Carter, president of Robinson Foundry, the decision to diversify production sounds simple.
Robinson Foundry has production expertise in green sand in the vertical separation iron business and has experience in melting and processing aluminum castings from foam loss.
The trick is to combine these two areas of expertise to improve
Economical quality casting.
The marriage was driven by a customer at Ford Motor.
, The company is looking for aluminum exhaust gas recycling gasket components in The Lost foam.
The problem is that components are not \"appropriate\" as costs\"
Effective choice of foam.
However, based on its experience in iron, Robinson Foundry knows that the aluminum design is well suited for a vertically split green sand type, as it can be core-packed and oriented in the mold.
While many of the same principles of shrinkage and fluid flow apply when converting components of vertically separated iron-made green sand casting into aluminum, Carter and Robinson both acknowledge that aluminum is a
\"We don\'t have books or documents that we can follow,\" Carter said . \".
\"In terms of component design and gate, we start from scratch.
\"For spacer parts, Robinson Foundry melted 319 aluminum in a previously developed crucble furnace for the loss of foam and cast it on one of its existing iron mold lines.
With the first fall, the company became the third independent foundry in the United StatesS. (
The aluminum casting & Engineering Company in Milwaukee and the Northern Aluminum Casting Company in Fond du Lac in Wisconsin are the other two)to production-
Casting Aluminum in vertical direction
Separate sand line.
The success of the spacer element has earned Robinson Foundry a \"reputation\" in aluminum green sand \"---
Engine export components of General Motors (GM)(Fig. 1).
GM also wants the volume of the parts to be processed and assembled to be 5000/day.
Robinson Foundry responded with a partnership with Latva Machine, Inc.
10,000, Building a, new hanbu New Harbor-sq-
On 1998, ft processing operation was carried out in the foundry.
The foundry now produces 15% of the machines in this factory).
The engine outlet components are made of 319 aluminum casting, paving the way for the foundry certification of GM as the first-class supplier of vertical split aluminum green sand casting. Safety-
Although the foundry has built its own niche market in the field of aluminum casting, it is still looking forward to the future.
\"In the automotive industry, everything is for weight loss,\" said sales manager Mark Kress . \".
\"Our future is to provide aluminum alternatives that meet the necessary mechanical properties of key components of iron safety.
Aluminum provides 50% weight reduction for our automotive customers.
Joe Robinson continued: \"We need to understand the market\'s recognition of security --
Key aluminum castings produced using our green sand casting method.
We went to 6 different brake suppliers.
Visited the engineering team with Big 3.
The key is whether the necessary attributes can be implemented and documented.
Customers are hesitant to adopt new technologies.
We have a lot to prove.
Robinson knows that it can achieve the necessary mechanical properties (
Stretch, elongation and fatigue life)
Aluminum has its current green sand system, but the consistency from operation to operation is not obvious.
Product consistency is mandatory if the customer is to be secure
Key components such as control arm, knuckles and brake parts, Carter said.
When a permanent mold is cast, the customer does not select an unverified process for aluminum (
Due to its low turbulence charge and cold modeling)
It has been well established.
In fact, the company is considering joining the permanent mold field, \"but it doesn\'t make sense to enter the market of a foundry with a lot of experience, says Joe Robinson.
This decision restored the foundry to its expertise in vertical separation of green sand molding and developed low pressure vertical separation of green sand pouring from Disa industrial company in Oswego, Illinois
We made this decision.
In the manufacturing process, there is a question, \"If a component is currently manufactured as cast iron in a vertically separated sand type, why not make it with aluminum? \"\' said Carter.
\"The key is to find a way to implement the necessary attributes.
\"In February 2000, Robinson Foundry became the first company in North America to install such casting systems (
Systems are also running in Austria, France and Germany).
At Robinson Foundry, system (Fig. 2)
By a 2. 2-
Ton bottom pressure downpour furnace working with molding line.
When the mold is ready to pour, the pouring mouth of the furnace inserts itself into the pouring mouth located in the lower part of the mold.
Pneumatic system Generation 1.
The pressure of 5 psi forces aluminum to enter the pouring system through the pouring mouth.
This force provides the operator with direct control over the flow rate of the melt and the start/stop of the pouring.
The target in the casting is a metal speed not higher than 0.
5 in/sec throughout the filling process.
In addition, when the metal flow rate enters the runner system of the mold, the metal flow rate must be increased to fill the casting cavity.
If the metal flows too fast in the gate system, it will erode the mold wall and cause inclusions.
If the mold cavity is filled too slowly, it will cause improper solidification of the casting.
The metal fills the cavity from the bottom (
Reduce the gate system size required for castings, thus increasing the output by up to 15% over conventional pouring).
After the filling is completed, push the sand core into the gate to prevent the metal from running back to the furnace when the pressure is released (
For more information, see \"new filling/feeding process for vertical production-
\"Modern Casting, April 2000, p. 54).
Robinson Foundry can cast 319 or with this system.
With up to 70% molds as the core, the foundry can produce up to 300 molds/hour (
10 seconds cycle time/mold)with 8-
12 Ib aluminum casting/mold.
The pouring furnace arrangement on this molding production line provides several key advantages for the treatment of molten aluminum: * extracting metal from the middle of the bath to ensure cleanliness, and minimize the chance of oxide inclusions from the melting surface;
* During sealing, degassing is carried out in the chamber of the Furnace, reducing the oxide that the melting material is exposed to the atmosphere and carried in the melting material;
* New molten aluminum can be fed into the pouring furnace during operation to increase productivity;
\"We can get the necessary mechanical properties through regular pouring in the M6, but this is not consistent enough for us,\" Carter said . \".
\"Bottom pouring ensures consistency in the market for safe key components.
\"Melting treatment and low-
The pressure bottom pouring allows Robinson to cast parts with a quiet filler.
This eliminates the erosion of the mold wall (Sand wrapping body
And reduce the molten aluminum turbulence caused by metal folding and oxide and gas trapping (microporosity)
Set during casting.
The result is a typical tensile strength of 40,000-
5-45,000 psi and elongation7%.
At present, the foundry has cast three production operations and four operations for the bottom casting system in its traditional mold production line.
One of the bottom pouring operations is the 356 aluminum steering knuckle for full-
Terrain application of casting plant at a speed of 40,000 pieces/year (
Demand is expected to be 80,000/year in the near future).
The aluminum expansion \"is similar to the lost foam, and the future of this production method depends on whether the components are designed to take advantage of the process,\" says Joe Robinson . \".
\"This is what we want to sell.
\"Robinson has created his own future in aluminum.
The foundry is building a new 30,000-sq-
The ft facility for this innovative process is expected to be operational next year.
Will melt in the new 6-ton high-
The efficiency shaft fumace and launder systems will deliver the melting to the pouring station.
In addition, two cold box core systems will be added to the foundry to supply the mold production line.
\"When we started selling our new features for the first time, we were selling a vision to determine the level of acceptance of the process,\" Carter said . \".
\"While prospects are still skeptical, stretch performance and results can be a great help to their understanding.
\"At the moment, the aluminum production of gravity pour is 70% and the aluminum production of bottom pour is 30%, but Carter expects these percentages to be reversed soon as the company is an unchallenged new technology
As Joe Robinson said, \"We \'ve been looking for better ways.
We think we have an untapped market in our hands.
Metal Casting in Alexandria, Alabama: 319, and aluminum alloy;
Balls and gray iron.
Mold ability: green sand divided vertically.
Core features: coolbox and shell.
Melting ability: careless induction and crucble pot.
Size: 120,000 square feet.
Main markets: cars, accessories, agriculture and heavy equipment.
Year of establishment: 1946
Factory officer: Joseph H. Robinson, Jr. , chairman;
President Jerry CarterMark A.
Chris, sales manager; Ryan H.
Robinson, manufacturing manager.
Robinson opens the door to lost foam casting and has recently received a lot of praise for its ability to cast complex geometry that can be eliminated-the-Road handling.
Companies such as General Motors and Saturn have invested in the future in the process.
However, back in the early 80 s, the future of losing the foam is not as bright as many foundry attempts (some half-hearted)
And failed in the process, making the process black-eyed in the design community.
Then there was Robinson Foundry, who accepted the process in both gray iron and aluminum, and became the first North American Foundry to enter foam casting.
\"We are facing a lot of offshore competition and we have to find a better way,\" says Joe Robinson . \".
While Robinson had a prototype success on the motor housing for the first time, the first commercial shipment was the gray iron exhaust elbow or Mercury Marine.
\"The only way to prove that the bubble is lost is to get the tools, but you can\'t get it without a large amount of money,\" Rickey Robinson said of early obstacles . \".
\"We took any foam we could get.
With regard to foam density, glue, paint and foam control, a lot of people already know today ---
When we don\'t know if what we do is right, we succeed.
Anyone who tells you about the process can\'t stand too much change and they don\'t see our operations and our success.
Bruce macmellon of wacon Engineering said that the participation of the Robinson Brothers was significant, not only because it was the first steel processing plant, but also because they did it without customers or markets.
\"They created a whole new look for the process, creating an appeal beyond the car.
\"Many also praised Robinson for having a further understanding of the process between the foundry and the terminalusers.
\"They know they need competitors to succeed, and they may lose the bubble if others join in and build credibility,\" McMellon said . \".
\"This is as important as their actual work on the casting.
\"Raymond Monroe\'s steel casting Association in the United States added that he was involved in the construction of the Saturn foam casting facility and wrote the first comprehensive bubble loss book: \"These two boys from Alabama can successfully sell the technology commercially ---
Especially parts that cannot be cast in any other way--
Opened a lot of eyes.
\"Two larger bubble genealogical trees missing from the United StatesS.
Casting Group into larger-
The foam production of the scale loss can also be traced back to Robinson.
Its steel business was eventually sold to citation bubble.
And its BodineRobinson joint
The risk of aluminum was sold to the Internet. Michael J.
A foundation built at Robinson Foundry opened the door in 1946 as a gray iron supplier for decorative castings and soil fittings.
Today, this business has developed into Robinson Group, including Foundry; the Robinson-
Latva processing facilities;
Robinson iron, expert in repairing landmark and decorative castings;
And Satterfield, Inc.
A company focusing on industrial supply, mechanical parts, electronics and special metal manufacturing.
The growth of the foundry witnessed the loss of foam casting in 80 years (
And 90 early subtraction)
And then turn to high after \'90
Vertical division of iron and aluminum production green sand operation.
In 1991, the foundry increased by three
Production line of Iron (
One of them is aluminum now).
For cast iron, the foundry is in two 15-
Ton of Coreless Induction cooker and hold in two 40-
Ton vertical channel furnace.
The kernel is generated during both the Coldbox and the shell.
There is pole casting on both iron lines.
The main products of the foundry in terms of iron include motor support and suspension support, shaft tube housing, oil cooler housing and commercial accessories, which cast more than 150 jobs per year for various customers.
Once the new facility of aluminum is completed, Robinson expects the casting production of iron to be divided into 40% (
80% toughness and 20% Gray)