SPECIALISTS IN THE PRODUCTION OF HIGH QUALITY SHELL & AIRSET CASTINGS IN VARIOUS GRADES OF IRON
Our large purpose-built facility in the West Midlands primarily produces complex, high tolerance shell
and airset castings for a variety of industries in various grades of iron.
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16,000m² Facility
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10,000kg of Iron Cast Daily (Single Shift)
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5 Induction Furnaces
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4 Two Station Shell Moulding Machines
Would you like to discuss a project?
Telephone: +44 (0) 121 556 4451
Email: sales@newbyfoundries.co.uk
100KG HIGH TOLERANCE CASTINGS
Facilitated by our unique vacuum backed shell moulding process to CT9 tolerance.
HIGH OR LOW VOLUME RUNS
From tens to tens of thousands, we have the flexibility to cater for both.
IATF & ISO Quality Management
Accredited to both IATF 16949 & ISO 9001 for the shell & airset processes.
PROCESSES
Primarily our iron foundry produces castings using the airset, shell moulding and unique vacuum-backed shell moulding processes but we also have greensand capabilities and an in-house 3D sand printer. Therefore, we can provide customers with the most suitable casting solution for many applications. Our range of processes also enables us to produce cost-effective casting iron in various quantities from tens to tens of thousands.
Find out more about the processes we offer below.
SHELL & VACUUM BACKED SHELL MOULDING
- Resin bonded using polygram machines
- Medium to high volume
- Plate size 600x400mm
- Up to 100kg
- CT9 tolerance
- IATF 16949
- Durable iron tooling
- Strong, complex core assemblies
- High tolerance
- Improved surface finish
- Vaccum backing plant
- up to 100kg
AIRSET
MOULDING
- Chemically bonded and hand rammed
- Low to medium volume
- Up to 250kg
- CT10 tolerance
- Resin tooling is available in various grades
- Suitable for large cores and castings
COLD BOX
CORE BLOWING
- Gas cured blown sand
- Used in combination with other processes
- Low to high volume
- Fast curing
- Resin tooling is available in various grades
- High tolerance
- Smooth surface finish
3D SAND PRINTING
- Furan system
- 1,800 x 1,000 x 700mm bed size
- Layer thickness: 0.28mm
- No tooling required
- Moulds and cores produced without tooling
Materials
We manufacture iron castings in a range of grades including grey, ductile, and vermicular irons, and alloy irons such as NiResist and SiMo. Customer specific grades are also available on request. Our 5 induction furnaces allow us to change grades within minutes and cast parts weighing from as little as 200g up to 250kg.
We can produce all grades of the following materials. Non-standard and customer specific grades are available on request.
Grey irons
High compression strength & dampening qualities.
Ductile irons
(spheroidal graphite, SG, or nodular) Ductile with a high tensile strength.
Vermicular graphite irons
Characteristics in-between grey and ductile irons.
Austempered ductile irons (ADI)
Heat treated for increased strength & wear resistance.
SiMo (Silicon Molybdenum) irons
Resists oxidisation at high temperatures.
NiResist irons
Resistant to corrosion at high temperature.
Newby Foundries are committed to sourcing materials from companies that share our values in relation to human rights, ethics and environmental responsibility. We demand our suppliers comply with our code of conduct, and meet our sustainability expectations, including conflict free sourcing of materials. To ensure this commitment is fulfilled Newby Foundries ensures that its products are produced using only materials which can be proven to have originated from non conflict sources.
Sectors
NEWBY FOUNDRIES OPERATE IN THE FOLLOWING INDUSTRIES:
We produce castings iron for a wide variety of OEMs in sectors such as automotive, hydraulic and pump components such as turbine housings, bearing housings, compressor covers, valve spools and pump bodies construction, pumps and hydraulics. We also make various general engineering castings.
Automotive
Hydraulic
PUMP
Defence
Construction
Engineering
EQUIPMENT
Design
- 5x SolidWorks CAD software licences
- MagmaSoft casting simulation software
Core making
- 9x shell core blowing machines
- Cold box core blowing machine
- CNC core drilling robot
Melting
- 4x 550kg induction furnaces
- 1x 350kg induction furnace
- 16 element spectrograph
Moulding
- 1,800 x 1,000 x 700mm furan 3D sand printer
- 4 x 2 station polygram shell moulding machines
- 10 ton per hour airset mixer
Sand reclamation
- Thermal sand reclamation plant
- £1.2m investment in 2012
- Self sufficient for coated shell sand
- Sand laboratory facilities
Blasting
- 3x tumble blast machines
- Table blast machine
- Nozzle blast machine
Fettling
- 4x CNC fettling robot
- Large CNC fettling robot
Measuring
- 3 axis coordinate measurement machine
- 7 laser 3D scanner
OTHER SERVICES
Discover the services Newby Foundries Iron can also assist with:
QUALITY
- Material testing laboratory
- Dimensional analysis reports
- PPAP & APQP
- MPI, DPI & X-ray
- Pressure testing
- Ultrasonic testing
Divisions
Explore the Newby Foundries Group
The Newby Foundries Group produce high quality castings in a variety of materials, sizes & finishes across our 4 sites. Our range of casting processes, combined with our ability to develop castings from prototype through to production means we can provide customers with an optimal casting solution for many applications.
CONTACT NEWBY FOUNDRIES IRON
Newby Foundries are specialists in the production of high quality shell & airset castings in various grades of iron.
For more specific enquiries for our individual foundries, please find contact details on our contact us page.
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Telephone: +44 (0) 121 556 4451
Email: sales@newbyfoundries.co.uk
Address:
Newby Foundries Ltd, Smith Rd, Wednesbury, West Midlands WS10 0PB
