Sand Foundry Casting
Sand Foundry Casting at Aurora Metals
At Aurora Metals, our expertise extends to sand casting of stainless steel, duplex stainless, and super duplex stainless alloys, offering versatility in material options and part complexity. Our air-set sand foundry is designed to provide our customers with short- to medium-run castings, allowing us complete flexibility to produce high-quality parts across a wide range of materials and applications.
Versatile Casting Capabilities
Our sand foundry casting process allows us to work with a variety of materials, including:
- Stainless steels
- Duplex stainless steels
- Super duplex stainless steels
- Cast iron
- Non-leaded Brass and bronze alloys
This versatility eliminates the need for separate sand facilities for each material, streamlining our production process and offering cost-effective solutions for our customers.
Superior Tolerances and Repeatability
We utilize air-set sand molds, which offer several advantages:
- Closer as-cast tolerances
- Reduced mold wall movement and distortion
- Superior repeatability, even on the smallest run quantities
These benefits ensure consistent, high-quality castings across production runs of all sizes.
In-House Tooling & Pattern Making
Our dedicated tool shop, staffed by full-time tool makers, provides complete in-house facilities for tooling and patternmaking. This capability allows us to:
- Create custom patterns for unique casting requirements
- Repair customer-supplied tooling
- Prepare tooling for our sand-casting process
Our in-house tooling and pattern making ensures quick turnaround times and maintains the highest quality standards for our casting patterns.
Advanced Metallurgical Control
Our all-electric induction furnace facility enables us to cast a broad range of alloys while maintaining tight metallurgical composition control. Key features include:
- Precise control over alloy composition
- Ability to cast a wide variety of ferrous and non-leaded non-ferrous alloys
Aurora Metals Division, LLC remains dedicated to pushing the boundaries of what's possible in precision casting.
Comprehensive Quality Assurance
We maintain rigorous quality control measures throughout our sand-casting process:
- Complete sand testing facility for grain size consistency, L.O.I.'s (loss on ignition), and tensile strengths for molding and core sands are typical examples of monitoring the process
- Lab spectrometers to verify chemical composition of each heat before
- Coordinate measuring machine for verifying patterns and intricate casting dimensions
Casting Specifications
Our sand foundry can accommodate a wide range of casting sizes and production volumes:
- Casting weights: 2 pounds to 250 pounds
- Typical production quantities: 1 piece to 500 pieces per month
What We Do
Our Services
Aurora Metals offers a comprehensive suite of precision casting services, catering to diverse industry needs:
Lead Lined Wood Doors
Customizable sizes and veneers with fire labels up to 90 minutes.
Lead Lined Control Frame and Hollow Metal Doors
Available in custom profiles.
Lead Drywall
Our lead drywall is designed for easy installation, ideal for various structural applications to shield against harmful radiation.
Protective Glass
We offer protective glass with standard to enhanced shielding options, including safety laminated glass for door lites and side lites, ensuring safety and visibility in critical areas.
Lead Lined Steel Welded Doors & Frames
Designed for extreme door weights, custom jamb depths, and profiles with special hardware reinforcements.
Linear Accelerator Doors and PET Shielding
Tailored design for heavy radiation shielding.
Lead Plywood Interlocking Panel Systems and Lead Bricks
ALLOYS
In addition to the alloys listed on our standard bronze alloy page, we offer the following selection of ferrous alloys. If you require an alloy not listed, please contact one of our sales engineers for more information.
| Alloy | Cast Grade Designation | Wrought Grade Designation | ASTM # |
| Iron | Cast Iron | Typical Class 25 | A48 |
| Corrosion Resistant Stainless Steel | CF3 | 304L | A352, 743, 744 |
| CF3M | 316L | A352, 743, 744 | |
| CF8 | 304 | A352, 743, 744 | |
| CF8M | 316 | A352, 743, 744 | |
| Copper Alloys | Refer to copper-based alloy charts. All of these alloys can be sand-cast, but the physical characteristics will differ. |
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| Other alloys may be available - please check with one of our Sales Engineers to determine availability. | |||