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As an introduction to Carley Foundry, Inc., we have outlined just few of our production capabilities:
GENERAL . . . Carley Foundry has been a family owned business for over 55 years. We pour a complete spectrum of closely controlled aluminum alloys in Green Sand, Dry Sand, Permanent Mold, Low Pressure Permanent Mold and Investment processes in a modern 178,000 ft^2 facility. These aluminum alloys include A201, 203, A206, 224, 242, 319, 354, C355, A356, A357, A390, 535, and 713. We also pour a variety of ferrous alloys in the Investment process.
ENGINEERING……We have 10 degreed engineers covering the disciplines of Mechanical Eng, Metallurgy, Physics, Industrial Engineering, & Manufacturing Technology as well as a strong group of technicians in Manufacturing & NDT. We have designed & built specialty machines and have on staff master electricians with excellent skills in robotics and control.
GREEN SAND CASTINGS . . . Our expertise in sand castings is in high integrity, complexly cored castings that require an excellent surface finish. The molding facilities include: Automatic 16X20, squeezers, cope and drag lines, roto-lift and loose floor molding. Our casting sizes range from 6” square to 50” square, with a maximum weight of 700 pounds.
DRY SAND AND CORE ROOM . . . One high-speed air set lines for intricate and highly accurate castings and is the mainstay of our larger core making. Castings in this process range from 6” square to 96”square with a maximum pour weight of 2000 pounds. We also have 3 Laempe L-50 high speed cold box machines Capable of blowing 350 pound cores, along with 5 shell core and 4 other cold box machines. Please refer to our equipment list for more details.
PERMANENT MOLD . . . Our permanent mold operation is more suited to long run production jobs. Our permanent mold machines are static, tilt pouring, 3 way, low pressure, stand alone custom molding cells, along with a 6 station rotary / robotic cell for higher production jobs and they all have their own dedicated furnaces. This results in greater production rates and maximum control of your castings.
INVESTMENT CASTINGS. . . We have the ability to provide precision investment castings (lost wax) in a variety of ferrous and non-ferrous alloys, compliant with aircraft & military specifications. Carley Foundry is able to provide the lower volume Rapid Prototypes in our hand dipping line or higher production volume through our 150 station robotically controlled dipping, shelling and temperature controlled drying system (New 10/2009).
PATTERN SHOP . . . Our roots are in pattern making, hence our craftsmen continue to make a significant amount of our tooling. We build wood, urethane, and metal patterns all types of core boxes, permanent molds, fixtures and gages. We have extensive experience and specialize in rapid prototyping of castings.
QUALITY SYSTEM . . . AS/EN/JISQ9100B / ISO 9001:2000 registered. The following are in-house capabilities that are NADCAP certified.
. . . . . X-Ray - Penetrant Inspection
. . . . . Metallurgical lab – Mechanical
. . . . . Heat Treating -
. . . . . Welding
I hope you find this information helpful when evaluating Carley Foundry, Inc. as a source for aluminum sand and permanent mold castings, and Ferrous & Non-ferrous Investment Castings. Visit us on the web if you can’t stop by soon!
Jamie Erickson firstname.lastname@example.org
763-205-8906 desk 612-961-8411 cell
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