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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
Highly Engineered Castings In addition to being the largest ingot mold supplier in North America, EEC produces high-quality engineered castings for industries in Power Generation, Mining Equipment, Dies, Machine Tools, Heavy Construction, Fluid Transfer & Wind Energy. The castings for these markets are either high grade gray iron or ductile iron, which exhibits high strength as well as good toughness and fatigue strength.
Gray Iron Castings – 2 to 145MT (160T)
Nodular Iron – 2 to 72 MT (80T)
Melt Shop Capabilities Three 55 T (50 M/T) Induction Furnaces
with charge preheater
Melt Capacity of 10,000 T (9,000MT )/month
Produce Gray & Ductile Iron
Sand system - 1 Walco and 1 Didion are supported by a total of 9 continuous mixers, which in total are capable of mixing & discharging sand at a rate of 300/2000 lbs (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 21' (6.4M) wide x 26.5 M (87') long x 2.4M (8') deep 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')
Finishing/Inspection Area
Mold Production
11
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.
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
Power Generation
Hubs
Bases
Transmission Components
Cast Shafts
Bearing Housings
Spindle Housings
Gear Box Components
Turbine Housings
Fossil Fuel Components
15‘ (4,600mm)
28.4T(25.8MT)
Machine Tool Components
Bases
Press Crowns Press Beds
Plates Tables
Segment 23’ (7M)
Column 12’ (3,700 mm) 11.2T (10.1 MT)
Columns
Fluid Handling
Suction Cover 5.3T (4.8MT)
Valve Bodies
Discs
Housings
13.8T (12.5MT) 10.7T (9.7MT)
Mining/ Pulverizing - Material Crushing
Grinding Mill Trunnion
Grinding Mill Head
Segment Liners
Forming Die
Pulverizing Base
EEC Engineering
MAGMASOFT Casting Simulation Software, network license SolidWorks
3 Dimensional Design Software, network licensed
AutoCAD 3D 3 seats
F.M.E.A. (Failure Mode & Effects Analysis) and APQP (Advanced Product Quality Planning) Training Kent State University
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
Summary of EEC’s Strengths 1. Owned by a billion dollar, debt free, privately held company specializing
in large, heavy section metal parts. 2. EGI’s commitment to EEC: 20% of annual tonnage goes to Ellwood Quality Steel (vertical integration) Over $18 million invested in EEC in the last 5 years.
3. Union Free Plant to assure “continuity of supply” along with EGI’s long term commitment.
4. Excess iron melt capacity and land to grow with customer requirements. 5. Diversity that supports long term survival during market cycles. 6. EEC’s commitment to continuous improvement Improved engineering and APQP planning Improved process controls to reduce variation and cost per ton Optimize and enhance the assets we have to control fixed costs for better customer
value.
Ellwood Engineered Castings 7158 Hubbard Masury Road
Hubbard, Ohio U.S.A.
Dan Rhoads - President [email protected] 330-568-3016 Greg Selip – VP Technical Services [email protected] 330-568-3009 Pat Callihan - VP Operations [email protected] 330-568-3034 Brian Connell – Director of Sales [email protected] 330-568-3040 Bob Scarmack - Ingot Mold Sales Mgr. [email protected] 330-568-3022 Tim Morrow – Sales Associate [email protected] 330-586-3046
Ph: 330.534.8668 - Fax: 330.534.0069
Email: [email protected] Web Site: www.ellwoodgroup.com