Operational Capabilities

Foundry

Metals

Ashland Operations produces a full spectrum of ASTM steel alloys and chrome irons. Steel groups include Carbon, Low Alloy, Nickel-based, Duplex, Austenitic and Super Austenitic, and Martensitic alloys.

Melt Equipment

The foundry utilizes 6 coreless furnaces ranging in size from 500 pound capacity up to 7,500 pound capacity. This allows Ashland to pour the wide range of aforementioned alloys and to pour a variety of batch sizes to meet customer demand and lead-times.

Ashland also utilizes an AOD which refines our steels and allows us to use less expensive raw materials while offering the highest quality metals. The AOD is rated at 6,000 pounds.

All metal chemistries are tested on our spectrometer and physical properties are checked to provide tensile, elongation, and yield data. All tapping and pouring temperatures are also checked and recorded.

Our metals are poured in Kal-tec lined ladles with teapot spouts to draw the metal from the bottom of the ladle to reduce defects.

The foundry can pour up to a 13,000 pound mold or a 7,500 pound casting dependent upon casting configuration. Melt capacity is approximately 50,000 gross pounds/shift.

Molding/Core making

Ashland has a core room that utilizes oil sand for small lacey cores and Pep Set for the rest of the cores. The cores are generally made in dump core boxes. Another core line, also utilizing Pep Set, doubles as a vertical molding line that can mold impellers and similar castings. Palmer mixers are utilized to mix the sand. There is also a portable mixer for Chromite and other specialty sands as needed. Ashland reclaims its sand with a Thermal Sand Reclaim system.

The three main molding lines utilize a Furan no-bake process and the molds range in size from 24” x 24” flaskless molds up to 96” x 96” molds made in steel flasks. (See attached chart. The three molding lines are a flaskless mold carousel 12 station line (6 cope and 6 drag), an Index flaskless line, and floor molding. These lines utilize Kloster and Palmer mixers.

Ashland utilizes ceramic filters, exothermic sleeves, Ventex tubes for venting cores, “chill” cores and ceramic gating systems as needed in molding and core making for its diverse requirements.

Pattern Shop

The pattern shop employs 5 journeymen pattern makers skilled in all aspects of producing foundry tooling. The shop is primarily utilized for gating and rigging and pattern maintenance repair. A network of outside shops is utilized for building new tooling and repairs as needed. Ashland uses ProCast solidification and modeling software to maximize yield and minimize defects.

All patterns and core boxes are computer catalogued and organized on racks.

Heat Treat/Upgrade/Cleaning

After shakeout in the foundry, the gates and risers are removed via Air Arc or plasma cutting. They are then cleaned in a large Pangborn shot blast and transported to one of three cleaning areas dependent upon casting size.

Castings are ground, inspected, welded (Mig/Tig) if needed, and heat treated.

Utilizes Miller welders and have three heat treat furnaces. The largest furnace is a Sauders which can anneal and harden. It can reach temperatures up to 2100 degrees. The next largest furnace is a Lindbergh which is used for solution annealing and reaches temperatures up to 2175 degrees.

Ashland also has a small batch L & L electric furnace that can reach temperatures up to 1800 degrees and is generally used for hardening of 1212 Carbon steel.

We can also do non-destructive testing such as LP testing and Mag particle. All welders are certified.

Machine Shop:

Scope

The machine shop supports Ashland Operations in two ways; they machine castings from the Ashland Foundry and can also machine castings, bar stock, plate, and fabrications from other sources. The machine shop is supported technically by two mechanical engineers and other skilled staff.

Customers can request purchase finish machined castings, therefore the machine shop provides a definite value-added process to Ashland’s products. We also have the added capability to paint castings prior to shipping.

Ashland machining as primarily a mid-size horizontal turning shop which also has two large vertical turning machines, one with live tooling. There is a lot of capability in smaller horizontal turning and milling as well.

We machine a wide variety of material; although we specialize in stainless steels and chrome irons, we can machine many of the exotic materials as well. We also turn large bar stock into shafts and related products.

We have EDM capability which we use to cut key ways into impellers. We also balance some smaller impellers as well.

Equipment

The shop has 36 CNC machines and 15 manual machines. Our layout and machines allows for single piece manufacturing.

Currently we are not able to machine the larger castings that are produced at Ashland Foundry such as lower and upper casings but we are looking into this as part of our growth strategy for the future.

Support

Both the Foundry and Machine Shop are supported by technical staff and QA staff. We have the capability of programming and fixturing our machines in-house. Our QA staff uses certified gauges, dimensional layouts, hardness test, and weld maps to help us to meet our customer quality requirements for their products.

 

Mold Line Pattern Board Size Flask: Y/N Sand Type
Carousel/Index 20" x 24" N Furan/No-Bake
Carousel/Index 27" x 34" N Furan/No-Bake
Carousel/Index 34" x 34" N Furan/No-Bake
Carousel/Index 42" x 42" N Furan/No-Bake
Carousel/Index 48" x 48" N Furan/No-Bake
Carousel/Index 54" x 54" N Furan/No-Bake
       
Vertical 24" x 36" (Nominal Size) N Pep-Set/No-Bake
       
Floor Molding 36" x 36" Y Furan/No-Bake
Floor Molding 50" x 50" Y Furan/No-Bake
Floor Molding 60" x 60" Y Furan/No-Bake
Floor Molding 60" x 72" Y Furan/No-Bake
Floor Molding 72" x 72" Y Furan/No-Bake
Floor Molding 78" x 78" Y Furan/No-Bake
Floor Molding 84" x 84" Y Furan/No-Bake
Floor Molding 96" x 96" Y Furan/No-Bake