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New Developments
Phenolic-Urethane sand mixer.
During the recent summer shutdown, Sawbrook Steel Castings uprgraded the mixing capabilities of the phenolic-urethane sand mixer in our core room. The new mixer is a model M-200 Palmer.The new mixer not only has a higher output of sand, as measured in pounds per minute, the upgrade has multiple sand hoppers that increases our flexibility of sand mixes. These sand hoppers allow the use of three different base sand formulas.
The M-200's chemical binder pumping system has increased our capabilities. The pumps permit different addition rates for each of the sand hoppers. The increased sand hopper and pumping options allows Sawbrook to optimize chemical addition rates and set times for increased efficiencies.
Click Here For Palmer M-200 Picture
Floatex Heavy-Duty Shakeout
In July, we installed a new Floatex (registered) 8' x 10' Heavy-Duty Shakeout. Ideal for jobbing foundries, the Floatex shakeout is used for the shakeout of castings, heavy flasks and mixed flask sizes. The new shakeout is especially beneficial for reducing sand lumps associated with chemically bonded molds.Click Here For Floatex Picture
Thermal Sand Reclaimer
Our newly installed Thermfire Sand Reclamation System has been in operation since September, 2000. Its purpose is to both reduce the amount of new sand purchased, and to reduce the amount of sand that is currently being discarded.
This equipment, when fully implemented, will result in Sawbrook Steel being able to lessen the impact future cost fluctuations have on our end product. This capital expenditure represents a continuing investment in our foundry, ensuring that we will continue to be competitive and timely on delivery, while maintaining a high quality standard.
Click Here For Thermfire Sand Reclamation Pictures
Solidification Modeling
Using AFS solidification software Version 4.2 and AFS 2000, we have found improved methods of risering and gating; increasing yield and controlling costs.Ladle Boards
Sawbrook Steel Castings is investigating the cost effectiveness of multi-use, highly insulating, and disposable ladle linings. Depending upon the size ladle, these liners are available in either one piece or segmented lining forms. The advantages of such a system is the potential improvements resulting from:
Click Here For Ladle Boards Picture
Calcium Injection
Sawbrook Steel Castings has begun using a metal treatment that produces beneficial changes in the deoxidization by-products found in steel castings. The treatment uses a calcium addition, accomplished by feeding into the molten steel, a Calcium-Silicon alloy encased in a cored steel jacket wire. The wire is metered into the heat at a controlled addition speed and amount.The Calcium reacts with the oxides and sulfides in the aluminum deoxidized steel. This reaction changes the particle hardness, chemistry, shape and buoyancy of inclusions. These modified inclusions more readily float to the top of the ladle, becoming trapped in the protective slag covering.
The inclusions that remain suspended in the melt are softer than non-modified particles. The softer particles greatly improve the machinability of the steel, acting as a tool lubricant. Initial machining results are very favorable.