Aluminum and Brass Sand Casting Foundry

Rising to the Challenge

NFCA customer had severe quality issues from another supplier. The part (a water outlet) was being produced as a low-pressure permanent mold casting.  The Tier I supplier was machining this thin wall (.180”) complex shape casting that required a sand core.  There was extensive machining on the part which was 100% leak tested after machining by the customer.  Impregnation was not allowed.

The Tier 1’s existing supplier was providing product with 40% fallout rate after machining and air decay leak test. And of course, the casting supplier wanted a price increase of 30%.

Quality Implementation

NFCA accepted the challenge.  Through the use of simulation modeling, it was determined that several external design changes were required.  With approval from the OEM customer the changes were implemented.  Within 6 months NFCA produced this part and continued for over 6 years with volumes averaging 240,000 parts annually.

Reducing Cost with Sand Casting

As a result NFCA’s Tier 1 supplier reduced their machining scrap from 40% to less than .5%, avoided a 30% price increase and satisfied their major targeted customer. NFCA’s internal scrap was less than 2% and productivity was improved compared to the permanent mold supplier by more than 700%.

Improved Logistics

Shipments went from the three daily shipments by previous supplier, to truckload quantities from NFCA delivered weekly.

The bottom line: A successful partnership through Casting Excellence

Alloy:    333F

Casting Wt:    1.66 lbs.            Minimum wall thickness: .180” (4.6mm)

Automatic green sand molding with sand core

Requirements: 100% leak test after extensive machining

No impregnation allowed