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General
Waukesha Foundry
Co., Inc. has been a producer of intricately-shaped cast components
for over 90 years. Our course has taken us through many markets;
but with consistent quality, customer service, an exceptional engineering
staff and a workforce with an average of 18 years experience, Waukesha
Foundry has met and surpassed our customers' most stringent requirements.
Engineering
The Waukesha
Foundry manufacturing and metallurgical engineers work in concert
with the customer to provide high quality cost effective designs
for castings. We can interface with various computer aided design
(CAD) systems, accepting two and three dimensional wire frame, fully
surfaced or solid models. Using CAD solidification programs to identify
problem areas before castings are produced means that effective,
efficient manufacturing processes can be developed, reducing lead
times, costs and ensuring consistent quality. more
info
Pattern
Shop
You can take
advantage of our full service pattern shop, provide us with patterns
or we can sub-contract pattern construction to a local pre-qualified
pattern shop. Our engineers work closely with the pattern makers
to ensure all pattern construction and adaptation is done to exact
engineering requirements.
Foundry
Molding:Based
on your part’s geometry, weight and quantity required, we select
a molding and coremaking process to best suite your needs. We offer
four separate molding processes:
Chemically
Bonded Sand – Also referred to as “No-bake”
uses a combination of high grade silica sand and chemical bonding
agents in manufacturing molds up to 102 in. square. This process
achieves superior mold strength and dimensional stability with excellent
surface quality. Patterns for this process are typically constructed
of wood or high performance plastics. With relatively low start
up costs this process is an excellent choice for low to medium volume
production.
Resin Shell
– In this process mold halves are made by applying heat-activated
resin-coated sand to a pre-heated metal pattern. The rigidly bonded
sand provides great reproducibility and produces castings nearer
to net shape with intricate detail, superior dimensional accuracy
and surface quality. Tooling for the shell process is considerably
more expensive than for the “No-bake” process as it is
more precise and must resist heat and abrasion. The shell process
is an excellent choice for medium to high volume production where
added value is utilized by the customer.
Replicast™
- In this process foam patterns, machined or die produced, are coated
with a refractory. The foam is then removed before pouring leaving
a ceramic shell somewhat similar to that of an investment casting.
This process allows us to cast thinner sections and internal features,
reduces machine stock and results in a lighter weight design with
near net shape. These advantages make Replicast™ an excellent
choice for low to medium volume production runs as well as rapid
prototyping. It is also a good choice for high volume applications
which are not suited to other casting processes.
Patternless
– Our newest process is a variation of the chemically bonded
process in which a customer’s drawings and/or CAD data is converted
directly into sand mold ready to pour. The Patternless process allows
us to satisfy our customer’s requirements for very low volume
production by eliminating the need for conventional pattern equipment.
Costs and lead times are significantly reduced making this process
ideal for applications in which the customer only requires one or
two parts which may not be needed again for a long period of time.
Our Patternless molding process envelope is 96” x 144”
x 36”.
Core Making:
Cores are produced in a variety of processes including oil sand,
no-bake and shell. Ceramic and isocure blown cores, if required,
are supplied by a certified vendor.
Melting
and Heat Treating
Waukesha
Foundry has three banks of induction furnaces and a two-ton electric
arc furnace to handle melting and pouring requirements from just
a few pounds to over eleven thousand pounds. Heat treating is performed
in house or by a certified vendor.
Casting
Upgrade
Our finishing
department is complete with arc burn-off, abrasive cutoff, grinding,
welding, steel shot and sand blast facilities. We offer an upgrade
program of grinding, welding and polishing designed to provide you
with a casting that meets or exceeds your specification. Welders
are certified to ASME Section IX, MIL-STD-248 and ASTM A488.
Non-Destructive
Examination
Waukesha
Foundry offers complete in-house non-destructive testing facilities.
Our radiographic inspection capabilities include a 300kv x-ray unit
and a Cobalt 60 source for inspection of materials up to six inches
thick. We also utilize several certified vendors with “high
energy” sources for inspection of materials up to eighteen
inches thick. We also offer magnetic particle inspection (wet fluorescent
method) and liquid penetrant inspection (water washable visible
dye method). Our experienced non-destructive testing staff includes
inspectors that are all ASNT Level II qualified plus a SNT-TC-1A
Level III certified inspector.
Laboratories
Waukesha
Foundry’s sand testing facilities are equipped to perform routine
sand and slurry testing. Our chemistry and metallurgical testing
facilities are equipped to perform chemical and mechanical properties
testing as well as corrosion and metallographic inspections. Special
testing, if required, is performed by a certified vendor.
Machining
and Fabrication
Waukesha
Foundry’s own full service machine shop, P & W Machine,
combined with various certified machining vendors gives us the ability
to satisfy all your post casting requirements. Post casting services
include: rough and/or finish machining, Blanchard grinding, polishing,
fabrication welding and assembly. Whatever your requirement, Waukesha
Foundry is your one stop shop for all your casting and finished
component needs.
Quality
Assurance Certifications
ISO 9001, ASME
Section III NCA3800, MIL-I-45208, and MIL-STD-45662.
ENGINEERING
CAPABILITIES
CAD/CAM
SOFTWARE
- AutoDesk
Mechanical Desktop6.0/ACAD 2000
- SurfCAM
5-axis with CATIA Translator
- SurfCAM Solids
Plus
CAD
DATA IMPORT FORMATS
We prefer to receive
data in two formats, STL (stereo lithography) and one other. While
STL is NOT useful for making parts or tooling, our solidification
analysis software can only accept STL imports. We request STL data
for all new parts.
We suggest sending drawings, which contain extensive text as .PDF
(Adobe Acrobat) files or as paper drawings, because most data transfer
modes have some degree of unreliability when converting text.
| Extension |
File
Type |
Notes |
| .DWG |
AutoCAD |
AutoCAD
native file format |
| .DXF |
AutoCAD |
Wireframes
and simple faces only. |
| .IGS,
.IGES |
IGES |
Wireframes and surfaces only. Text is unreliable. |
| .STEP |
STEP |
Imported
via AutoDesk’s STEP translator. Maybe unreliable. Not fully
tested. |
| .DSN |
SurfCAM |
SurfCAM
native file format. |
| .MODEL |
CATIA |
Imported via SurfCAM’s translator. Wireframes and surfaces
only. Text is unreliable. No known problems. |
| .X_T,
.X_B |
ParaSolids |
Common solid modeling kernel used by Unigraphics, SolidWorks
and Solid Edge. No known problems. |
| .SAT |
ACIS |
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TRANSFER
METHODS
E-mail
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