GREEN SAND ALUMINUM FOUNDRY PROCESSES

Established in 1990, The Edelbrock sand foundry specializes in A356 and 808 aluminum. Its 115,000 square feet of working space has been called the most modern green sand foundry west of the Mississippi.

The Edelbrock foundry uses state-of-the-art technology in all three of its molding lines. Metal is melted in two modern tower jet melter furnaces and held in three reverb natural gas furnaces. Two fully automated cope and drag molding lines are supported by a high-volume green sand handling system. In addition, the foundry utilizes a flask-less match-plate molding machine which is specialized in high volume production.

Processes and Capabilities

Three automated mold lines: 2 automated 20″ X 30″ cope & drag mold lines are equipped with BMM Molding machines and a Sinto brand 20″ X 24″ match-plate flask-less molding machine.

Dry Sand Molding: A Dry Sand continuous mixer adds to our molding process and rapid prototyping capabilities.

Castings: Automated lines are capable of complex, core intensive castings of up to 60-pounds.

Sand Handling Systems: The sand foundry has a self-contained sand handling system capable of processing 100 tons of sand per hour by mixing 5,000-pound batches of sand every 90 seconds. Each batch is tested by a Hartley Automatic Controller for proper moisture content & compactability. Each molding machine is replenished automatically by a complex conveyor system traveling through 400 feet of underground tunnels.

Core Production: Edelbrock core production is anchored by (24) core machines, this includes (4) Iso-cure (cold box) machines and (20) B&P shell core machines.

Robotic Ladling Systems: 2 ABB and one Shamrock 100 lb. bottom pour ladling robots pour aluminum at a preset value for unmatched consistency. The unique bottom pour design fills the ladle below the metal surface resulting in reduced dross and turbulence for a more consistent casting quality.

Core Removal: Edelbrock assures quality through attention to detail. Utilizing traditional and state-of-the-art equipment, Edelbrock produces the finest quality cores for high casting quality. After the castings are poured, they are sent through Edelbrock’s finishing department, where the cores are removed using automated Hershal and A-Frame vibratory machines and finally prepared for heat treatment or machining.

Robotic Clean-up: Hand finishing and high-tech robotic equipment are used to deliver high quality machine ready castings.