Foundry - © Brockmoor Foundry

Foundry

Metal is supplied by 2 8 Tonne 6KVA Medium Frequency Furnaces, which have close capture hoods and load cells. A Predetermined weight of material is automatically charged into the furnaces.

Metal transfer from furnace to the Fischer Converter

The metal having been released to the foundry, is poured into a +GF+ converter, prior to being moved to the treatment area.

Having completed the treatment process, the metal is transferred to and ABB 6 Tonne presspour.

Metal Transfer from the Converter to the ABB 6 Tonne presspour

Automated pouring with inoculant addition

The pouring process is automatically controlled by a Sert optical system and Inoculant is added to the metal stream proportionally to the pouring rate.

Moulds are produced on a disforma 3030, high pressure, horizontal green sand plant. Castings ranging from 2.00kg to 85.00kg are produced on this section.

Kardex unit storing frequently required tooling

Pattern Equipment is stored in a Kardex unit adjacent to the moulding machine.

The sand is removed from the castings by a Joost shacker, prior to entering Didion rotary drum. The sand then passes through a Schenk sand cooler and into a 300 tonne silo grading system. Mulling of the sand takes place in an Eric 60 tonne per unit with automatic moisture control.

Bird eye view of Core Production facility

The primary method of core product is by cold box, this being supplemented by Pepset and Hot box. Cold box cores are produced on 3*Laempe LL20's, 1 Loramendi and 2 Fordath machines. Hot box, by 2 MCM5 machines.

Dependent on application, cores are dipped and stoved to prior being released to the foundry.

Laempe slide Show

First Visual Inspection operation after shotblast operation

The casting, having passed the the Didion drum travel on a Magdali belt, where the runners and risers are removed by Hydraulic wedges, prior to passing through a BMD continuous shot blast and a first off visual inspection.

Grinding and fettling takes on 1 of 4 automatic units, which is supplemented by manual pedestal unit and conventional fettling booths.

Additional automatic robot fettling unit

Although 95% of our production is As-cast, we still retain considerably capacity to heat treat castings through a top hat or batch furnaces. We also offer a sub-contract service to foundries for the heat treatment of castings.

Prior to painting, machining or despatch the casting will receive a final shot blast and a 100& visual inspection.

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Brockmoor Foundry Co. Ltd. The Leys, Brockmoor, Brierley Hill, West Midlands, DY5 3UJ
Tel: 01384 480026 | Fax: 01384 480032 | Email: info@brockmoor.co.uk

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