Manufacturing Processes

Aarrowcast’s metal foundry has the flexibility to work with various iron types and coring needs, and can fulfill low to high volume orders. From engineering and metallurgy to pattern design, tooling builds, core assembly, and ultimately melting and molding, our manufacturing processes allow us to create your custom casting from start to finish or get involved at any point in the process.

At Aarrowcast, we believe customer collaboration can lead to better results and the best value for your solution since you know your product better than anyone. That’s why we have resources ready to enable and support customer collaboration, in order to best meet your needs.

Aarrowcast also offers a variety of value added services through a group of approved heat treating, painting and machining suppliers. We bring greater value to our customers by coordinating these operations and delivering finished, ready-to-install parts.

Engineering

Give us your blueprint or model, and Aarrowcast’s team of engineers will determine the best way to manufacture your component. We collaborate with our clients to custom design their specific components or reverse engineer them in order to maximize production efficiencies. Using state-of-the-art technology, our engineers provide input in order to improve castings and reduce overall costs during all stages of our manufacturing process. We extensively use MAGMA Solidification Analysis software to virtually simulate, evaluate and assess our metalcastings, which allows us to optimize gating development, maximize mold filling and cooling abilities, and predict internal shrinkage porosity. We also support all major CAD platforms. Ultimately, we will make sure your final castings are effective while your project runs as efficiently as possible.

Mold Filling Video Solidification Video

Metallurgy

Aarrowcast employs experts in the field of metallurgy who intimately understand the physical and chemical behaviors of iron, as well as the technology of this metal. This expertise allows us to determine the optimal characteristics for producing specified shapes or properties of iron components that will ultimately be used by our customers in their end-use products.

Flexibility – Iron Grades Produced

Gray Iron

Per ASTM A48

  • G20
  • G25
  • G30
  • G35
  • G40
  • European Equivalent Specifications can also be produced

Ductile Iron

Per ASTM A536

  • 60-40-18
  • 65-45-12
  • 80-50-06
  • 100-70-03
  • European Equivalent Specifications can also be produced   EN-GJS-400-18LT per EN 1563

Austempered Ductile Iron (ADI)

Per ASTM A897

  • 110-70-11
  • 130-90-09
  • 150-110-07

Solid Solution Strengthened Ferritic Iron (SSSF)

Per EN 1563:2012

  • GJS 450-18
  • GJS 500-14
  • GJS 600-10

High Silicon Moly

  • Per customer spec

60-40-18 Ductile Iron properties can be achieved WITHOUT heat treat

Molding

Aarrowcast provides a wide range of molding capabilities, including the largest automatic green sand machine, the Georg Fischer.

Cores

Complex core assemblies are efficiently handled in the Aarrowcast process, which allows intricate castings to be made to very stringent quality levels.

 Aarrowcast’s completely automated, conveyorized core room facility is engineered to process Isocure and Pepset cores. Our core production consists of a Laempe L120 (360 lb. maximum core), a Laempe L150 (900 lb. maximum core) and a Laempe L50 (100 lb. maximum core), which are capable of blowing one-piece cores for an axle housing. Staffed around the clock, other equipment in our core room includes:

  • Laempe: L50, L120, L150
  • 13 Redford Isocure Machines – both vertical and horizontal core machines
  • Air-Set line

Melting

Aarrowcast’s Melting Department features 6, 9-ton Brown Boveri Coreless Induction Furnaces. On-floor operators, charting for statistical process control, ensure quality assurance. Each charge is tested for temperature, carbon equivalency, total carbon and silicon content.

A dispatch monorail system transfers the hot metal from the melt deck to the individual molding and pouring lines. Superior grade raw materials—such as low sulfur-pig iron, low sulphur steel and returns—ensures consistent metallurgy and excellent machinability. Auto-pour capabilities in conjunction with a post inoculation feeder (PIF) allow for complete metal grade versatility.

Pattern Shop & Tooling Transfers

Aarrowcast’s Pattern Shop is dedicated to work with Manufacturing & Engineering on the following:

  • Cost reductions
  • Yield improvements
  • Gating / design / improvements
  • On time new tooling builds
  • Continual process improvements with outside pattern shops
  • Tooling maintenance