Bell City Foundry has three (3) different types of Moulding Equipment. Each type of Moulding Equipment requires a different size pattern as well each machine yields different average of moulds per hour.
We have two (2) Hunter 10 Automated Automatic Moulding Machine. The size of the Pattern Equipment is 14” x 19”. This machine produces on average 75 moulds per hour.
We have a Koyo Vertical Moulding Machine. The size of the Pattern Equipment is 16” x 20”. This machine produces on average 175 moulds per hour
We have a Disa Forma 3030 Horizontal Moulding Machine. The size of the Pattern Equipment is 20” x 26”. This machine produces on average 100 moulds per hour
Bell City Foundry has two (2) different types of Core Moulding Equipment. We have a Shell Core equipment and Cold Box Process equipment.
We have two (2) Harrison (1612 Model Number) Shell Core machines. Shell Sand is a resin coated sand excellent for use for small cores and where storage is required. Large cores can create gas problems in castings due to raw sand in the bodies of the cores.
We have three (3) different sizes of Laempe Core Moulding Equipment:
Laempe 5 Core machine is a 25 pound capacity Cold Box Process. This is used for small cores and high production levels. The typical cycle time is less than 15 seconds.
Laempe 10 Core machine is a 50 pound capacity Cold Box Process. This is used for medium cores and high production levels. The typical cycle time is less than 30 seconds.
Laempe 20 Core machine is an 80 pound capacity Cold Box Process. This is used for large cores and high production levels. The typical cycle time is less than 45 seconds
Bell City Foundry uses Inductotherm Furnaces for melting.
We have Inductotherm 2500 kilo watt Furnaces, high frequency coreless power supply connected to two (2) 6000 pounds (3 US Tons) furnaces. Each melt is started with an empty furnace (hot lining). This provides tremendous alloy versatility and the highest degree of safety in the melting operation.
Inductotherm 30,000 lbs (15 US Tons) useable pressurized Holding Furnace for grey iron production. – This furnace provide an excellent metallurgical and thermal fly wheel effect to control chemistry and pouring temperature to the moulding lines.
Bell City Foundry does in house testing on our metal with the use of the following equipment:
Leed & Northrup Digi Lab for initial chemistry checks on the melting furnaces (Grey and Ductile irons)
Chamatzu Spectrographic for final chemistry in all furnaces and ladle chemistries in the production of Grey and Ductile irons.
For independent testing we do have an outside Laboratory that is able to do additional testing.
In addition to all the above equipment, Bell City Foundry uses the below equipment at different points of the processing of the metal.
Simpson Technologies 22” (100 ton/hour) continuous Sand Muller with compatibility controller.
Wheelabrator Tumble blasts 28 cubic foot shot cleaner.
Didion 100 ton an hour sand and casting separation drum.
Didion 40 ton an hour media cleaning drum.
100 ton an hour rotary screen. This is used to separate core butts from return sand. This is fed by conveyor belts with a magnetic head pulley to separate metallic from return sand.
200 ton sand storage silo, fed by bucket elevator and equipped with a live bin bottom to stop rat tailing associated with sand storage bins.
30,000 CFM Wet Scrubber is used for air quality control on all sand carrying devices.
Grinding Room equipped with several 30” wheel stand grinders, assorted bench grinders, drill presses and hand operated tools (pneumatic and electrical).
Here at Bell City Foundry we produce multiple grades of gray and ductile iron. The difference in these types of iron are as follows:
Gray Iron got its name from its dull gray surface appearance when it fractures. Gray Iron is the most widely used cast material based on weight. Benefits of Gray Iron are the following:
Gray Iron is used for housings where tensile strength is non-critical, such as internal combustion engine, cylinder blocks, pump housings, valve bodies, electrical boxes, and decorative castings. Gray Iron’s high thermal conductivity allows for such uses as cast iron cookware and disc brake rotors.
Ductile Iron is when the graphite is like a pillow and acts as “crack-arresters” to give ductility and toughness superior to all other cast irons. Benefits of Ductile Iron are the following:
Ductile iron is much more flexible and elastic, due to its nodular graphite inclusions. Ductile iron is specifically useful in automotive components, agricultural tractors, and oil well pumps, where strength needs surpass that of aluminum but does not necessarily require steel.