Steel Casting

Here at Hampton Foundry we run a no bake system.  Once the pattern has been inspected by the pattern shop it is then transported to the mold line.  We are able to run 5 to 6 small patterns at once along with 2 big patterns also.   

The molder operator will put the patterns on the line to be run and also give the proper core boxes to the core maker.  The molder operator will then place all the proper inserts onto the pattern IE: Kalserts- Kalpurs – chills- Insulators.  Once this is done the molder operator will then place all the open risers.  The molder operator will now fill the mold with the sand from the mold machine.  If there is a core that needs to be made the core maker will get sand from the mold machine and fill the core box.  Once the mold is filled with sand the molder operator will then strike off the extra sand and remove all open risers and caps for the Kalpurs as well. 

Once the mold is set up the mold closer will then push the mold into the roll over and it will roll the mold over so that the mold will then come out of the pattern.  The mold closer will then atand up the cope and vent all cores and risers.  The mold closer will then remove all loose sand and dirt from the mold and cover it with a mold wash.  The mold wash will give the casting a smoother surface and prevent burnt in sand once the mold is poured. The mold closer will then close the mold and place it on the proper line for pouring. 

The steel is then melted in 1 ton induction furnaces and is a mixture of scrap steel and returns from other castings.  We then add the alloys to the furnace to the desired material.  Once the steel is liquid we then pull a pre pour sample and run it on the spectrograph.  Once we have the data we will then make the proper adjustments to the alloys as needed.  Once the steel is with in the specs of the proper material we are then ready to tap out the furnace and pour the steel.

Grinding Services:  Once the gating has been removed we will grind the contact pads flush with the part.  We will also remove all parting lines.  Once this is done we check the casting for burnt in sand and will also remove that as well.  We currently have 4 hand grinding stations all are equipped with 6” horizontal grinders, 9” horizontal grinders as well as 2 90 degree grinders 1 with a cap stone and 1 with a cup stone.  Each bay also has a dye grinder that can be switched from a hone stone to a carbide bit.  We also have 2 snag grinding stations that we utilize as well for smaller parts.