At ThyssenKrupp Waupaca, we apply science to a greater extent than most metal casters. From our top leaders to our manufacturing teams, metallurgists are involved in controlling process consistency and continuously improving our technology. Our metallurgists and engineers designed proprietary processes and customized equipment to monitor iron temperature, additives, casting materials and processes down to a hyper-detailed level.
For customers, this ensures our products are consistently durable and reliable. Our degree of automation reduces overall manufacturing costs. And our metallurgists and casting experts are “on call” to effectively problem solve design or production adjustments.
Laser scanned dimensional analysis provides 3-D scan of parts so we are able to provide dimensional consistency in castings for more accurate machining and product performance. We also monitor post-machining balance so finished castings will perform with uniform balance.
3-D solidification modeling simulates the entire casting process using a 3D model before we enter production. Computer models of the mold, core, pattern and casting are created; we simulate the gating and pouring and project cooling rates. The simulation allows us to identify potential issues and adjust individual elements of the process before the casting reaches the foundry floor; saving time and money.
Digital imaging allows ThyssenKrupp Waupaca to inspect and characterize the microstructure of a casting. We look at the graphite for size, volume and structure and inspect the elements within the iron. Metallurgists are able to ensure our customers that castings were made to specifications.
Robotic core production automates the process including unloading, coating and finishing cores. This allows us to increase volume and efficiency while maintaining quality and competitive pricing.
Automated iron pouring means that iron is automatically dispensed into a green sand mold; a standard at ThyssenKrupp Waupaca. We hold ourselves to the highest quality standards and automatic pouring is a means to address the need for more precisely repeatable and controlled processes that improved casting quality and consistency.
Vertically parted high pressure molding machines are custom designed, engineered and manufactured for ThyssenKrupp Waupaca by ThyssenKrupp Waupaca. These hybrid machines earned a patent in 2010 and feature unmatched speed and reliability offering customers price advantages due to volume production.
Additional testing technology at ThyssenKrupp Waupaca demonstrates our dedication to quality, and includes complete metallurgical labs. Testing procedures are designed to eliminate trial and error and subjectivity of more traditional methods.
- Resonant frequency testing tests the uniformity in a structure and the density of a casting to ensure the casting will not produce unwanted noise. In the case of automotive brake discs, this ensures rotors will operate without excessive noise.
- Wedge penetration testing measures the tensile strength of the component using a section of gray iron from an actual finished casting (not a cast bar).
- Advanced thermal arrest system establishes the properties of the iron. By examining the solidification rate of the iron, metallurgists can determine the solidity of the casting. During the cooling process as iron goes from a liquid to a solid, it goes through phase transformations which release or absorb heat. By measuring these “events” we are able to predict if the castings will be solid and if the structure can be machined.
- Tensile testing measures the tensile strength, yield strength and elongation for iron casting materials. Dimensions are very important for the accurate test result, so at ThyssenKrupp Waupaca, we use a computer lathe, or CNC, to machine tensile bars to a high degree of accuracy so the sample is representative of how the casting will be machined. This ensures the castings meet specifications.