aluminum sand castings, finishing & prototyping for many industries

CASE STUDIES


With Epcor you get more than just the best aluminum castings.
You also get exceptional design & engineering services.

CHALLENGE
Automotive Part - A Tier 1 machining facility needed assistance designing a high performing complex casting.

EPCOR SOLUTION
Epcor worked with machining facility and the end customer to design a part for manufacturability - at a reduced cost.

RESULTS
The Epcor Engineering team designed a better performing part - at less cost exceeding all of the requirements.

 


With Epcor you get more than just the best aluminum castings.
You also get exceptional design & engineering services.

CHALLENGE
Automotive Parts – Tier 1 machining facility experienced high levels of scrap (post machining) due to porosity and leakers.

EPCOR SOLUTION
Epcor designed and engineered a new gating system that reduced turbulence and oxide entrapment which eliminated the leaks and subsequent scrap.

RESULTS
The Epcor engineering team designed a better performing part.  Providing the most reliable parts with a zero defect rate is a hallmark of the design & engineering team at Epcor.

Do you have a quality problem  that you would like evaluated by the Epcor design & engineering team?

 


SUPERCHARGED Modern Muscle Cars
Deserve a Super Tight & Leak-free Casting from Epcor

Oil Filter Adapter Requirements

  • 8 Cores
  • 319 Alloy
  • 4.0mm wall thickness
  • Engine coolant & oil within the same part separated by a 4mm wall
  • Pressure Tightness: Leak rate of 1.5cc @ 20psi

The Epcor engineering team designed a better performing part. Providing the most reliable parts with a zero defect rate is a hallmark of the design & engineering team at Epcor.

 


Casting of Aluminum Supercharger / Turbocharger Components

These castings featured dimensions of 22” x 18” x 6” and were produced from A356 T6 aluminum, cast on our DISA Match 130 and Roberts Sinto FBO #3 20x24” high speed mold machines which allowed us to meet tolerances of ±.010”. After the parts were cast and de-cored they are trimmed in an automated trim cell, before being shot blasting, plated, and powder coating. We manufactured up to 50,000 of these components for this customer in the South, with 10 week lead times. These can be factory or aftermarket parts to increase the performance of cars by increasing the flow of air into the engine.

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Casting of Aluminum Oil Filter Adapters/Coolers

We received this part as rush job because the customer’s previous supplier had gone out of business. Since our customer needed the parts immediately, the first run was produced with existing tooling while we developed the new tooling. With the use of our solidification simulation software we were able to anticipate machining challenges ahead of time, and discovered several areas of concern. This advanced capability allowed us to make key modifications that dramatically increased productivity. The first time through put exceeding 99%, compared to their former supplier’s through put which was below 80%.

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Aluminum Casting of an Exhaust Gas Recirculation Duct & Air Intake Manifold

Their original design would have required a supplier to the truck industry, 15 cores, and would have been very costly to cast. We worked with them to redesign the part with a single core without affecting the performance of the part, this decreased the cost of the part tenfold. The 6” by 4” casting is composed of 356 aluminum, and cast utilizing our DISA Match 130 and Roberts Sinto FBO #3 20x24” high speed mold machines, this capability allowed us to meet tolerances of ±.010”. Quality control is maintained through dimensional, inspections as well as ball and flow checking. We redesigned this high volume production part and supplied it within budget and on time.

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Casting of Aluminum Fueling Components

An industry leader in the fluid transfer component industry was on the brink of losing their customer’s business due to missed delivery dates, they counted on Epcor Foundry, a division of Seilkop Industries, Inc. to provide them with precision aluminum castings. Their previous castings supplier had provided them with poor quality castings, requiring them to scrap nearly 50% of the parts and fall behind on their production schedule. Scrap castings cost time and money in sorting and missing parts. We are able to provide the customer with castings at a scrap rate of less than 1%.

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