Steloy Processes

The process of taking, clean and sound alloys and castings them into custom engineered designs takes a variety of processes to ensure all your castings can be manufactured properly and consistently under the management of our experienced Foundry team.

Image: Steloy Castings sand casting process photo
Sand Casting

Sand casting is one of the oldest methods for producing castings.

A wood pattern is required to form the sand into the desired engineered design. Our in-house pattern shop produces patterns with one of our three Computer Numeric Control (CNC) routers ensuring accurate and repeatable results.

Steloy has taken this basic sand casting method and created three streamlined sand molding lines at each facility,

These highly efficient production lines mix the raw sand and binders, form the molds, prepare them for casting and deliver them to the melt line for the actual casting process.

This mechanized and controlled process ensures constant and repeatable results at an efficient cost point.

Image: Steloy Castings process photo
Large Castings

Some designs are too large to produce on the ‘Line’ and these castings are made by hand by trained foundry artisans.

Casting of this nature can be up to 2 metric tons in finished weight and can be produced up to 5 meters in length. Each hand-crafted mold in made, prepared and inspected before it is closed and delivered for the casting process.

Castings made with sand molding can be produced to API 560 and ASTM A297, ASTM A351 and EN 10295 specifications. Other application specific specifications also can address and met during the production process.

Centrifugal Casting Process

Tubular products are made utilizing the centrifugal casting process.

In this process, permanent steel molds are rotated at high RPMs to generate gravitational forces in excess of 80 times the force of gravity before the introduction of our molten alloys into the rotating mold. This rotational force spins the fluid alloy into the tubular shape of the mold.

Key advantage of this process is that the most dense, and sound elements are pushed to the outer diameter of the castings and any oxides, which are less dense, are subsequently forces to the inside diameter of the casting. For process tubing, the inner diameter is machined away leaving a defect free and sound tubular wall. Casting diameters range from 80mm to 830mm. Wall thickness is determined by the amount of alloy poured into each casting. Castings made in this process comply with ASTM A608 and A530. For structural supports, the inner diameter materials remain in the as-cast condition.

Small weight and high volume castings are most efficiently produced utilizing the investment casting process. With Investment casting the high cost of tooling is prohibitive. The need for high volume of castings to off set this cost is required. The advantage of this process is through the utilization of a ceramic mold, accurate results can be achieved with minimal post casting finishing work. This reduces the handling and finishing costs delivering a high quality, low cost casting.