Our lives are filled with metal objects. We sometimes take for granted that the metal wheels on the train or the metal tap that we turn on are all part of our everyday lives. The sheer number of items made from metal demonstrates its versatility – and the ability to cast metal objects that are durable and complex with minimal machining is what we are all about.
Richmond Industries, Inc. is a manufacturer of quality brass, bronze and aluminum sand castings that currently operates out of a 40,000 square foot facility in Dayton, New Jersey.
Casting is the process where metal shapes are produced by filling voids in molds with liquid metal. We specialize in sand casting. The basic steps in the casting process include:
- Pattern making
- Molding, melting and pouring
- Inspections and pressure testing
In the casting process, the ‘pattern’ is the replica of the intended object (such as a machine part or metal wheel). Patterns used in casting may be made of wood, metal or plastic. To produce a quality casting, it is essential that the pattern is carefully designed and constructed. At Richmond Industries, we can either create a new pattern for you, or alter an existing one to fit your needs.
Our complete pattern shop has the capabilities to mount patterns as well as add markings or modify runners, gating and risers to adjust for production anomalies. This inhouse capability means that we can provide quick turnaround of any adjustments needed to achieve client timelines.
Molding, Melting and Pouring in the Foundry
Molding is the process of preparing to receive molten metal and the mold can be reusable or non-reusable, depending on what it is made of. The most widely used non-reusable mold method is sand casting, a process where rated ‘green’ sand is rammed around the pattern, a support is fixed, the pattern is removed and then the melted metal is poured into the mold.
There are two categories of metals that castings are produced from – ferrous (metal that contains iron) and non-ferrous (metals that no NOT contain iron). Richmond Industries is a non-ferrous foundry.
Our foundry consists of two separate sand systems which feed a 14 by 19 Hunter 10H and a 20 by 20 BMM (British Molding Machine). These molding lines are supported by six induction furnaces and three separate Inductotherm power supplies. ( 1- 750KW dual trak, and 2 – 500KW dual traks).
Inspections and Pressure Testing
All of our work is subject to rigorous quality inspections and pressure testing. Richmond Industries is equipped with a pressure test area with the capabilities of air testing to 100 psi and water pressure testing up to 5,000 psi. Upon request, Richmond will work with the customer to develop the method, test fixtures, pressure level and exposure time for testing casting integrity prior to shipment.
In addition to high quality casted parts, Richmond can manage your needs for a broad array of value-added services, including machining, painting, polishing, plating, assembly as well as provide tooling. Third party inspection is also available upon request.
A “complete” alloy listing is now available.