Learn from one of the nation’s most experienced aluminum foundries why choosing a foundry with multiple furnaces is important, versus one with just a few.
The typical aluminum sand foundry in the United States today pours more than one alloy. The 2 most commonly poured aluminum alloys today are 319 and 356. Here at Precision Enterprises, we also pour 319SR Alloy, Almag 535, and Tenzaloy 713, among others.
The 319 alloy is an aluminum alloy commonly used in the casting industry, particularly for making automotive and aerospace parts. This alloy is known for its good castability, strength, and resistance to corrosion.
The 356 alloy is an aluminum alloy widely used in the casting industry due to its excellent castability, good mechanical properties, and high corrosion resistance. It is particularly favored for applications where a good combination of strength and ductility is required.
What about Foundry Furnaces?
When it comes to furnaces, the typical melting capacity of a furnace in an aluminum sand foundry is between 200 – 2000 pounds. A large percentage of these foundries are job shops, meaning they run multiple jobs per shift. Each job may require a different alloy. If they only have a few furnaces, the possibility of contamination of alloys is increased.
To avoid contamination in the furnace before moving to the next job, the furnace must be purged. It is very time-consuming to purge an aluminum furnace, meaning completely clean it so there is no leftover metal in the furnace.
Certifying Alloys
Today’s metal smelters are experts in certifying the alloys they produce for foundries. This is a multi-step process including but not limited to raw material inspection, initial sampling, chemical composition analysis, mechanical and physical property testing, documentation and certification, and finally quality control.
The specifications of these alloys are held very closely for purposes of the end use of the casting. So, if the foundries do not purge the alloys from the active furnaces, and mix in other alloys into a common furnace, you get contamination of the alloys.
The solution to this issue, you guessed it – multiple furnaces. Here at Precision Enterprises, we have 13 furnaces, each of which is dedicated to a particular allow to help eliminate the chance of metal contamination. We don’t stop there though. With ISO Q9001:2015 certified facilities, we offer documented, published, and auditable procedures that ensure accuracy and high-quality production standards.
More Ways to Aluminum Foundries Can Avoid Contamination of Alloys
Here is a list of several ways foundries can contaminate their alloys. Make sure you ask these questions/check this list before contracting with an aluminum foundry.
- Choose a foundry that has dedicated furnaces for each alloy they pour!
- Do you have multiple dedicated furnaces for each alloy you pour?
- Have you audited your metal supplier? And does he certify his metal?
- Do you color code your metal as it is delivered from your smelter before placing it on the foundry floor? (Precision spray paints the metal while it’s still on the pallets delivered to our foundry. Each alloy has its own space and color on the foundry floor).
- Are the foundry patterns stamped with the specific alloy called out for? Both gates and risers? (When these are cut off in the finishing room, these gates and risers can be used as remelts (job permitting) and will signify to the furnace tenders what alloy these are. They will not be remelted in a dis-similar furnace.)
- Is each casting marked with its designated alloy?
- Is each furnace marked clearly as to which alloy it is dedicated for all to see?
The Takeaway
The takeaway is an aluminum foundry with only 1 or 2 furnaces has a higher possibility of cross-contamination between alloys. Choose a foundry that has multiple dedicated furnaces, like Precision Enterprises.
Some Other Reasons to Choose Precision Enterprises for Your Aluminum Foundry Needs
Precision Enterprises has been in business since 1945, and has satisfied customers worldwide with unparalleled service and expertise. Consistency from part to part, run to run, is what our customers have come to expect….and we deliver….parts to print, on time, and competitively priced. At Precision Enterprises, you’ll find a solid team of experienced professionals, focused on customer service and attention to every detail. We are family-owned and operated for over 70 years.
If you are considering an aluminum sand casting foundry, or simply want to discuss the options available to you, we encourage you to reach out. We’re here to help you navigate this complex process and find the best solutions tailored to your unique needs.
No responses yet