Foundry Management & Technology
April 2008

Ross Aluminum Casting Expands Permanent-Mold Capacity

Published April 11, 2008

New melting furnace, launder line, handling system

Ross Aluminum Castings L.L.C. reports that it recently increased its production capacity for permanent-mold castings by approximately 50% with the addition of a new melting and pouring line. The Sidney, OH, foundry had been concerned primarily with green sand and no-bake molding, as well as finishing of aluminum castings.

The company supplies aluminum castings to manufacturers of fuel pumps, hydraulic valves, and gear boxes for aerospace applications. Ross Aluminum also produces a range of aluminum castings for specialty and high-performance automotive and diesel truck markets, as well as for general manufacturing applications. It continues to offer sand-cast products, too, and most of its castings can be offered fully finished and machined.

Prior to the recent expansion, the company details, Ross Aluminum Castings had invested in a 12,000-ft2 facility dedicated to producing castings for a single customer. There, it installed a 4,000-lb/hour Modern Equipment Co. Jet Melter.

Now, that furnace has been supplemented by a 75-ft long, integrated launder line that supplies molten aluminum to eight permanent-mold casting production cells. This system uses in-line filtration and rotary degassing to ensure the specified metal quality.

Also, a new ABB robotic cell has been installed, combining knockout and sawing, to improve handling of larger aluminum castings (over 100 lb.)

A company statement says this expansion “demonstrates that Ross is committed to implementing lean concepts throughout our facility.”

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Modern Casting Magazine
April 2008

Ross Aluminum Increases Capacity

Released on March 25, 2008

Ross Aluminum Castings LLC, Sidney, Ohio, has increased its aluminum permanent mold casting capacity by about 50%, according to a company press release.

Advanced Metals Group LLC, which counts Ross as a member company, last month announced expansions at two of its other metalcasting facilities—U.S. Castings, Entiat, Wash., and Mabry Castings. A statement issued by Ross indicated that, like its co-members, the company “is committed to implementing lean concepts throughout [its] facility” along with the expansion.

Prior to the addition, Ross’ production stemmed more from its green sand and nobake lines; a 4,000 lbs./hour furnace was installed primarily to feed metal to those processes. That furnace now has been supplemented by a 75-ft. long integrated molten aluminum launder line that provides metal to eight permanent mold casting production cells. A new robotic combination knockout and saw cell also was installed to improve handling of aluminum castings in excess of 100 lbs.

Officials for Ross said the company would continue to provide aluminum castings to manufacturers of fuel pumps and hydraulic valves, as well as gearboxes to the aerospace industry and a range of castings to the specialty and high performance automotive, general manufacturing and diesel truck industries