2007 Trimester Review - Ellwood Engineered Castings

ELLWOOD ENGINEERED CASTING
Hubbard, OH
a DIVISION OF Ellwood Group, Inc.
Ellwood Group, Inc.
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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
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Steelmaking
Forging
• Heat Treatment
• Machining
• Casting
Heavy Metallurgical Section – Highly Engineered Products
Preferred Supplier to Global Customer-Base
Ellwood Group Inc
EGI
Ellwood City, PA
MELTING
CASTING
EQS
New Castle, PA
Ingot
ENS
Irvine, PA
Ingot
EEC
Hubbard, OH
Iron Castings
FORGING
ECF
Ellwood City, New
Castle, Corry, PA
Open Die
ECDG
Closed Die
ETF–H
Houston, TX
MACHINING
ENF
Irvine, Warren, PA
Finish & Semi-Finish
ETM
Titusville, PA
ECG
Finish Machining
ETF – N
Navasota, TX
ECM
Hermitage, PA
Repair Shop
EAC
Rural Hall , NC
ENC
Irvine, PA
Finish Machine
ENC
Irvine, PA
Closed Die - CGF
Crankshafts
Cleveland, OH Closed
Die – CGF
Crankshafts
ENCS
Hermitage, PA
Repair Shop
ERM
Houston, TX
Finish Machining
STEEL
DISTRIBUTION
ESS
New Castle, PA
UNISTEEL
Detroit, MI
Walter Metals
Hudson, OH
Ellwood
Specialty
Metals
LaSalle, Ont
OTHER
EMT
Ellwood City. PA
EEC
ENS
Ellwood Engineered Casting
Ingot Molds and Iron Castings
Ellwood National Steel
Forging Quality Ingots
Ellwood City Forge
Open Die Forging
EQS
ECF
ECG
ERM
Ellwood Crankshaft Group
Open and Closed Die
Forged Crankshafts
Ellwood Rose Machine
HBM/VTL Product
Ellwood Quality Steels
Forging Quality Ingots
ENF
ESS
ECDG
Ellwood National Forge
Ellwood Specialty Steel
Tool and Die Steel Distribution
Long Product - Hollows
Ellwood Closed Die Group
Closed Die Forgings
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EGI Markets Served
($000)
200,000
EGI Growth – 1984 to 2015 (Projected)
($000)
1,600,000
Acquisitions
180,000
Cap Ex
1,400,000
Sales
160,000
1,200,000
1,000,000
120,000
100,000
800,000
80,000
600,000
60,000
400,000
40,000
200,000
20,000
0
0
84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 P
Sales
Capital Expenditures/Acquisitions
140,000
1984-2015P:
Acquisitions: $274,338,000
Capital Expenditures: $1,153,536,000
Sales $15,369,365,000
Ellwood Engineered Castings
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
Produce Gray & Ductile Iron
Melt Capacity of 10,000 T (9,072M/T )/month
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Material Specifications
EEC Grade
ASTM
DIN 1693
DIN EN 1563
UK
new BS
Germany
W.-Nr.
France AFNOR
1003
A48, class 20 B
GG 10
Grade 100
0.601
Ft 10 D
1010
A48, class 25 B
GG 15
Grade 150
0.6015
Ft 15 D
1238
A48, class 30 B
GG 20
Grade 200
0.602
Ft 20 D
1239
A48, class 35 B
1340
A48, class 40 B
Grade 250
0.6025
Ft 25 D
EN-GJS-500-7U
500/7
0.705
GS 500-7
EN-GJS-450-10
450/10
Grade 220
GG 25
3040
GGG 50
3245
3345
A536, 65-45-12
GGG 40
EN-GJS-400-15
420-12
0.704
FGS 400-12
3346
A536, 80-55-06
GGG 60
EN-GJS-600-3U
600/3
0.706
FGS 600-3
3338
A536, 80-55-06
GGG 60
EN-GJS-600-3U
600/3
0.706
FGS 600-3
3145
A536, 60-40-18
GGG 40.3
LG
370/17
0.7043
FGS 370-17
Additional CUSTOM MATERIAL SPECIFICATIONS available on request
NDT Testing Equipment
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Ultrasonic (UT)-Krautkramer USN 58L w/DGS software
Magnetic Particle (MT)-Parker Probe Y7
Die Penetrant (PT)-DP51
Visual (VT)-SCRATA Visual Comparator Plates
NDT Certifications
 ASNT Level III
 ASNT Level III
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ASNT Level II
EGI Level III
EEC Level II
CWI
PT (die penetrant)
MT (magnetic particle)
VT (visual)
UT (ultra-sonic)
UT (ultra-sonic)
American Welding Society
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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.
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Mold Production
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')
Molding Area
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Drying Oven – Cheek & Core
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Teaming/Pouring Floors
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Shake Out Area
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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
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
Plug Bottom -1.6M x 2.8M
(62"x 109") Forging Molds
Open Top -2.1M x 2.7M
(82"x 106") Forge Mold
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Finishing/Inspection Area
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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”)
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Assorted Molds
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Mold Design
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Iron Properties
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Geometrical Considerations
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Thermal stresses
Mold Design Considerations
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Taper
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H/D ratio
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Smooth walled
or corrugated
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Wall Thickness
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Corner Radius
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Curvature
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Steelworks Practices
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Ingot Mold Temperature at start of cast (~100°C is ideal)
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Ingot Mold cooling after use
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Adequate space for uniform heat dissipation
Handling
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Slow cool in air
Ingot Mold spacing for teeming
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Preheat when cold
Avoid rough handling during stripping
Internal Surface Conditioning Program
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Remove oxidized layer and shallow cracks
Foundry Processes
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Chemistry Control
Effects of C, Si, Mn, S, Ti
 Deleterious effects of Pb, Cr, P
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Solidification Control
Inoculation
 Teeming
 “Shakeout” time
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Effects of Elements in Gray Iron
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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
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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
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Inoculation
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Gating and Pouring
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“Shakeout” time
Foundry Practices
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Inoculation - Control of solidification by the addition of
FeSi, Al, Ca, etc. in the iron prior to pouring
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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
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Cooling rate after solidification is critical factor in obtaining optimum
microstructure and resultant mold life
Premature “shakeout” produces a fast post-solidification cooling rate
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High residual stresses
Excessive pearlite in the microstructure
Poor mechanical Properties
Summary
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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.
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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
Ph: 330.534.8668 - Fax: 330.534.0069
Email: EECsales@elwd.com Web Site: www.ellwoodengineeredcastings.com