Production
Melting
Epcor Foundry offers a diverse range of metal casting solutions, including alloys such as 319, 356, and 357, catering to various industry needs. With our in-line filtration systems, we ensure the purity and quality of the molten metal, enhancing the integrity of our castings and minimizing defects. Our dedication to utilizing high-quality alloys and implementing advanced filtration techniques underscores our commitment to delivering superior products that meet the highest standards of excellence.
PLC Controls
Epcor Foundry employs advanced PLC furnace controls to regulate temperature and ensure precise pouring temperatures, enhancing efficiency and consistency throughout the production process. Our utilization of immersion elements for control further optimizes furnace temperature stability, allowing precise casting parameters.
Temperature Data Retention
Epcor Foundry employs live feed and retention approaches that are tied to specific production runs, utilizing unique date codes for tracking and control. This meticulous approach ensures that each casting was produced under optimal temperature conditions throughout the pouring process, guaranteeing consistent quality. By implementing tailored temperature parameters and integrating individualized date coding systems, Epcor Foundry upholds its commitment to delivering superior aluminum castings.
Metal Cleanliness
Epcor Foundry prioritizes metal cleanliness through rigorous filtration and fluxing procedures, ensuring the production of world-class pressure-tight castings. Our stringent fluxing techniques, effectively remove impurities and contaminants from the molten metal. As a result, our castings exhibit exceptional integrity and durability, meeting the highest standards for pressure-tight applications.
Molding
Automatic molding in green sand on DISA and Sinto machines stands as a hallmark of modern foundry technology, offering unparalleled process stability and efficiency. These advanced machines are engineered with precision control mechanisms that ensure consistent and reliable molding processes. By precisely regulating parameters such as sand compaction pressure, mold release, and pattern alignment, DISA and Sinto machines minimize variability throughout production. This stability not only reduces the occurrence of defects but also enhances the predictability of outcomes, instilling confidence in the molding process.
In addition to bolstering process stability, automatic molding delivers remarkable efficiency gains. The integration of automated controls streamlines operations, minimizing downtime and optimizing resource utilization. With precise control over factors like sand distribution and compaction pressure, these machines can achieve higher levels of productivity while minimizing material waste. Furthermore, the elimination of manual interventions reduces the likelihood of errors and ensures consistent performance, allowing foundries to meet stringent production targets with greater ease and reliability.
Overall, the combination of process stability and efficiency presents a transformative solution for foundries seeking to enhance their competitive edge. By harnessing technologies to maintain process stability and maximize throughput, these machines empower us to deliver high-quality castings at scale, all while minimizing costs.
Castings
Epcor Foundry specializes in the production of green sand aluminum castings, offering components that meet the highest industry standards while catering to a diverse range of client needs. Here are key points highlighting their expertise:
- Process Stability: Epcor Foundry prioritizes process stability in its operations, employing advanced molding techniques and precise equipment to ensure consistent quality throughout production.
- Efficiency: Through the integration of cutting-edge technologies and streamlined workflows, Epcor maximizes efficiency, reducing lead times and material waste while maintaining exceptional performance standards.
- Highly Cored and Complex Castings: Specializing in highly cored and complex aluminum castings, Epcor tackles intricate geometries with finesse. Leveraging advanced simulation tools and rigorous testing, we deliver leak-tight components with unparalleled accuracy.
- Scalability: Epcor’s operations are adaptable to varying production scales, accommodating orders ranging from low-volume prototypes to high-volume productions numbering in the hundreds of thousands per year. This versatility underscores their commitment to excellence and customer satisfaction in the green sand aluminum casting industry.
Core Removal
Our core knockout processes have undergone a transformative evolution with the integration of PLC-controls repeatedly remove cores from our thin-walled castings. These advanced systems not only enhance process reliability but also minimizes the risk of damage to the thin-walled castings, ensuring the preservation of their structural integrity and dimensional accuracy.
The pneumatic knockout hammers demonstrate remarkable capabilities tailored specifically for delicate core removal in thin-walled castings. Utilizing controlled air pressure, these hammers deliver precise and uniform strikes, dislodging cores with the utmost care and precision. Their ability to exert controlled force minimizes the risk of surface imperfections or deformation, maintaining the impeccable quality required in critical applications. As a result, we can achieve consistent and defect free core removal, even in the most challenging of casting geometries.