ellwood engineered casting machine . long products - hollows . ellwood texas forge . ... four planer...
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ELLWOOD ENGINEERED CASTING Hubbard, OH
a DIVISION OF Ellwood Group, Inc.
Ellwood Group, Inc. ● Celebrating 102 Years – Since 1910 ● Family-Owned – 4th Generation of Leadership ● Sales in excess of $1 billion USD ● Debt-free Organic and Acquisition-based Growth ● 2,250 employees in USA (PA,OH,MI,TX) and Canada ● Vertically Integrated – Market Facing Divisions
● Steelmaking • Heat Treatment • Casting ● Forging • Machining
● Heavy Metallurgical Section – Highly Engineered Products ● Preferred Supplier to Global Customer-Base
Ellwood Group Inc EGI
Ellwood City, PA
MELTING
EQS New Castle, PA
Ingot
ENS Irvine, PA
Ingot
CASTING
EEC Hubbard, OH Iron Castings
FORGING
ECF Ellwood City, New Castle, Corry, PA
Open Die
ETF - H Houston, TX Closed Die
ETF – N Navasota, TX
Closed Die
EAC Rural Hall , NC
Closed Die
ENC Irvine, PA
Closed Die - CGF Crankshafts
Cleveland, OH Closed Die – CGF
Crankshafts
MACHINING
ENF Irvine, Warren, PA
Finish & Semi-Finish
ETM Titusville, PA
ECG Finish Machining
ECM Hermitage, PA
Repair Shop
ENC Irvine, PA
Finish Machine
ENCS Hermitage, PA
Repair Shop
STEEL DISTRIBUTION
ESS New Castle, PA
UNISTEEL Detroit, MI
Walter Metals Hudson, OH
Ellwood Specialty
Metals LaSalle, Ont
OTHER
EMT Ellwood City. PA
Ellwood Quality Steels Forging Quality Ingot
Ellwood Crankshaft Group Open & Closed-Die Crankshafts
Ellwood National Forge Finish Machine
Long Products - Hollows
Ellwood Texas Forge Closed-Die Forging
Ellwood Specialty Steel Die Steel Distribution
ECG
ESS
ETF
ENF
EQS
Ellwood City Forge Open-Die Forging
ECF
EEC
Power Gen 23%
Oil & Gas 22%
Military 13%
Mining 6%
Railroad 5%
Automotive 5%
Power Transmission 5%
Aerospace/ Commercial 4%
Metal Manufacturing 4%
Marine/ Shipbuilding 4%
Other 3%
Machinery 3%
Infrastructure & Construction
3%
EGI Markets Served
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Ingot Molds - EEC Core Competency
EEC's mold designs range up to 6M long (20') consumable electrode molds to 35 M/T (39T) for super alloy ingots, to mammoth 143 M/T (157T) forging ingot molds. Our line of ingot mold products includes: Stools, Sprue Plates, Center Runners, Hot Top Castings and Slag Pots.
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Melt Shop Capabilities
Three 55 T (50 M/T) Induction Furnaces with charge preheater
Melt Capacity of 10,000 T (9,072M/T )/month
Produce Gray & Ductile Iron
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ASNT Level III PT (die penetrant) ASNT Level III MT (magnetic particle) ASNT Level II VT (visual) EGI Level III UT (ultra-sonic) EEC Level II UT (ultra-sonic) CWI American Welding Society
Ultrasonic (UT)-Krautkramer USN 58L w/DGS software Magnetic Particle (MT)-Parker Probe Y7 Die Penetrant (PT)-DP51 Visual (VT)-SCRATA Visual Comparator Plates
UK Germany new BS W.-Nr.
1003 A48, class 20 B GG 10 Grade 100 0.601 Ft 10 D1010 A48, class 25 B GG 15 Grade 150 0.6015 Ft 15 D1238 A48, class 30 B GG 20 Grade 200 0.602 Ft 20 D1239 A48, class 35 B Grade 2201340 A48, class 40 B GG 25 Grade 250 0.6025 Ft 25 D
3040 GGG 50 EN-GJS-500-7U 500/7 0.705 GS 500-73245 EN-GJS-450-10 450/103345 A536, 65-45-12 GGG 40 EN-GJS-400-15 420-12 0.704 FGS 400-123346 A536, 80-55-06 GGG 60 EN-GJS-600-3U 600/3 0.706 FGS 600-33338 A536, 80-55-06 GGG 60 EN-GJS-600-3U 600/3 0.706 FGS 600-33145 A536, 60-40-18 GGG 40.3 LG 370/17 0.7043 FGS 370-17
France AFNOREEC Grade ASTM DIN 1693 DIN EN 1563
Material Specifications
NDT Certifications
NDT Testing Equipment
Additional CUSTOM MATERIAL SPECIFICATIONS available on request
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Pattern Facility
EEC uses wood, laminate & foam patterns that are typically sourced from outside pattern shops. EEC performs regular pattern maintenance & constructs custom blocks for truck, rail & container shipments.
Sand system - 1 Walco and 1 Didion are supported by a total of 7 continuous mixers, which in total are capable of mixing & discharging sand at a rate of 300 - 2000 lbs (136 - 909 kg) per minute. Our on-site sand reclamation system, which can process up to 90% of reclaim sand guarantees that sand is conditioned to ensure optimal properties when blended. Chemically bonded sand molds (Furan).
Pit Molding - Up to 20' ( 6.1 M ) wide x 133' (40.5 M) long x 6' (1.8 M) deep and 6.4 M (21') wide x 87' (26.5 M) long x 8' (2.4 M) deep
Floor Molding Mobile mixer capable of 1 T (909 kg ) /min. with 90 T (81.6 M/T ) capacity Flask sizes up to 3.7M (12') X 6.7M (22') rectangular and 4.9M (16') square with Mold heights up to 4.3M (14')
Mold Production
Machining Capabilities
Four planer mills with size capability up to 2,921 mm (115'') wide x 1,980 mm (78")
high x 3,810 mm (150'') long and 82 M/T (90T) Radial drill capable of parts up to 1,220 mm (48") high on floor and hole size up to 101 mm (4''). Drill up to 1,828 mm (72") diameter by 3,655 mm (144") high
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Planer - 2.1M (84") 25MT (27.5) Forging Mold
Planer -2.1M (84") 18M/T(20T)Slab Mold
Milling Top & Bottom Insures Machine Surface to Machine Surface Fit on Stool
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Corrugated 25M/T (27.5T) Forge Mold
Open Top -2.1M x 2.7M (82"x 106") Forge Mold
Plug Bottom -1.6M x 2.8M (62"x 109") Forging Molds
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145M/T (160T) Cylindrical Forging Mold 3,302mm (10'8") Dia. x 3,810mm (12'5")
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82 M/T (92T) Cylindrical Forging Mold 3,302mm (7’7") Dia. x 3,048mm (10')
119 M/T (131T) Cylindrical Forging Mold 2,743mm (9’)Dia. X 3,912mm (12’8”)
Mold Design
Iron Properties
Geometrical Considerations
Thermal stresses
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Mold Design Considerations
Taper
H/D ratio Smooth walled or corrugated Wall Thickness Corner Radius Curvature
Steelworks Practices
Ingot Mold Temperature at start of cast (~100°C is ideal) Preheat when cold
Ingot Mold cooling after use Slow cool in air
Ingot Mold spacing for teeming Adequate space for uniform heat dissipation
Handling Avoid rough handling during stripping
Internal Surface Conditioning Program Remove oxidized layer and shallow cracks
Foundry Processes
Chemistry Control Effects of C, Si, Mn, S, Ti Deleterious effects of Pb, Cr, P
Solidification Control Inoculation Teeming “Shakeout” time
Effects of Elements in Gray Iron
Carbon and Silicon (C.E.) Increases graphite volume and coarseness Reduces Tensile Strength
Manganese and Sulfur MnS promotes graphite nucleation Refine graphite Promote Pearlite
Titanium Refines graphite Increases ferrite
Deleterious Elements
Lead Produces abnormal graphite (spiky, mesh, Widmanstätten)
Chromium Causes shorter, thinner graphite flakes Can form large carbide particles
Phosphorus Can form FeP eutectic phase
Foundry Practices
Inoculation Gating and Pouring “Shakeout” time
Foundry Practices Inoculation - Control of solidification by the addition of
FeSi, Al, Ca, etc. in the iron prior to pouring Promotes small, uniform “Type A” graphite flakes by providing
nucleation sites Prevents under cooling and “chill” (formation of primary carbides)
“Shakeout” Practice - removal of the cast iron mold from the molding sand
Cooling rate after solidification is critical factor in obtaining optimum microstructure and resultant mold life
Premature “shakeout” produces a fast post-solidification cooling rate High residual stresses Excessive pearlite in the microstructure Poor mechanical Properties
Summary
Large ingot molds are exposed to severe temperature gradients and stresses
Optimum mold life can be achieved with: Selection of the cast iron (gray or ductile) Mold Design (wall thickness, corner radii, etc.) Steelworks Practices (preheating, cooling, spacing,
handling, conditioning) Foundry Practices (chemistry control, inoculation,
gating/pouring, shakeout control)
Ellwood Engineered Castings 7158 Hubbard Masury Road
Hubbard, Ohio U.S.A.
Dan Rhoads - President drhoads@elwd.com 330-568-3016 Greg Selip – VP Technical Services gselip@elwd.com 330-568-3009 Pat Callihan - VP Operations pcallihan@elwd.com 330-568-3034 Brian Connell – Director of Sales bconnell@elwd.com 330-568-3040 Bob Scarmack - Ingot Mold Sales Mgr. rscarmack@elwd.com 330-568-3022 Tim Morrow - Sales Associate tmorrow@elwd.com 330-568-3046
Ph: 330.534.8668 - Fax: 330.534.0069
Email: EECsales@elwd.com Web Site: www.ellwoodgroup.com
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