Eagle Foundry is a jobbing foundry that produces over 13,000 different parts. Using a sodium silicate no-bake process, Eagle pours high-chrome white iron, chrome moly, heat-resistant stainless, tool steel, manganese and low alloy steels at temperatures ranging from 2,550° to 3,000° F in castings up to 2,000 pounds. The foundry operation needed to achieve compliance with OSHA silica dust permissible exposure limits (PEL) without compromising product quality, process efficiency or economic performance.
Eagle replaced their entire silica sand system with ACCUCAST ID (intermediate density) 70 ceramic casting media. The ACCUCAST ceramic casting media is a manufactured product that is chemically inert and compatible with the various resin systems. It is engineered to provide increased thermal stability and pellet strength for greater casting quality and precision, increased media recycle life, and reduced media consumption. ACCUCAST ceramic media produces no respirable silica dust.
Extensive testing has proven that ACCUCAST ceramic casting media, unlike silica sand, produces no respirable silica dust, so it easily complies with OSHA’s PEL regulation.
After several product cycles to optimize operations for the new casting media, Eagle reported improved casting surface finish, with castings meeting dimensional tolerance targets. They experienced reduced resin requirements and eliminated the requirement for additional mold reinforcement and the use of a mold and core wash. Cleaning times were reduced, in one instance from 50 minutes with sand to 10 minutes with ACCUCAST.
Media reclamation was significantly improved. Overall media consumption was reduced, which also resulted in reduced disposal volumes and replacement costs.