We are committed to providing the highest quality metal castings possible. Our team of experts is dedicated to ensuring that every part we produce meets or exceeds our customers’ expectations. We use only the best materials and equipment available to ensure that our castings are of the highest quality. Our quality control processes are second to none, and we are constantly working to improve our processes to ensure that we continue to provide the best possible service to our customers.
The Air Set Molding process is used for extremely large castings with highly complex geometries. Molds are comprised of chemically bonded dry sand and are suitable for complex shapes with multiple center sections.
We take pride in being one of the leading producers of large aluminum castings. The Air Set Molding process allows customers with demanding combinations of size and complexity to attain the desired end product in a single casting.
The process often forms a two-part mold made of silica sand mixed with furan and urethane binders, having a top and bottom, termed cope and drag. There are six steps in this process:
The process requires graded kiln dried sand, which is mechanically mixed with a resin to bind the sand together. A chemical hardener is then added to the sand mix, which reacts with the binder and begins to set the sand into a solid form
Our Air Set Molding process is best suited to larger, heavier, and intricate castings, and the sand used can be kept to a minimum without compromising quality so production costs are reduced.
Some advantages are:
We utilize an environmentally friendly binder system that allows us to maximize the benefits that our Air Set Molding process can offer
The V-Process not only saves the cost of sand binders, but all the cost of sand mixing, testing and disposal/reclamation. Even pattern life is extended because the pattern is only contacted by the plastic; therefore sand doesn’t cause wear. When pattern changes are required, they are easy to alter at a low cost
The V-Process is known for not requiring a draft that reduces weight and machining. This is due to the lubricity of the plastic film which expands slightly when the vacuum is drawn in the flask
The process has high dimensional accuracy, with a tolerance of ±0.010 in for the first inch and ±0.002 in/in thereafter. Cross-sections as small as 0.090 in (2.3 mm) are possible
125-150 RMS is the norm. Cast surface of 200 or better, based on The Aluminum Association of America STD AA-C5-E18
The Green Sand Casting (or Sand Casting) is the most commonly used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy, in today’s casting industry.
With Green Sand Casting, its versatility allows A&B’s produce small parts that weigh less than one pound or large parts that weight several tons. These casting parts are high quality and very cost effective
This process is used for volumes from one to thousands, and for small, simple parts to large, complex shapes. Holes and internal details can be cast using removable sand cores, made from core boxes
The Green Sand Casting enables A&B’s foundry to leverage the cost savings, process efficiency and flexibility of vertical casting technology
The material costs for Green Sand Casting are low and this process is exceptionally flexible. The mold material is also reclaimable, with between 90 and 95% of the sand being recycled, although new sand and additions are required to make up for the discarded loss
Some advantages of Green Sand Casting are:
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