Erie Bronze and Aluminum Company had a huge upgrade for our green sand casting foundry that specializes in non-ferrous (non-leaded) bronze and aluminum alloys for a variety of different industrial applications that require a casting manufacturer with DISA Match 20/24.
Erie Bronze & Aluminum is beyond excited to announce yet another machine upgrade for production. As of April 2024, we have replaced our former Harrison N28 26×26 Automatic Molding Machine with the state-of-the-art DISA MATCH 20/24 Molding System. The DISA MATCH is the most durable and precise green-sand match plate system available in the market today and is based on horizontal pouring and vertical blow and squeeze. The sand blow system used in the DISA MATCH is based on 50 years of experience and will effectively fill molds, even the ones with deep pockets, without the need for additional equipment or resources. With the machine’s swift and accurate pattern changes being paired with an operating interface that is extremely user-friendly, the DISA MATCH allows foundries like ours to reach the lowest cost per casting, even on short runs.
DISA Advantages: Core Setting, Production Speed, & Tight Tolerances
This superior piece of equipment for aluminum bronze casting manufacturing comes with an automatic Core Setter, which increases the speed of production from our former 10–15 molds per hour to a max of 145 cored molds per hour now! The best part is that even with this massive increase in the production speed, the molding machine tolerance still delivers a maximum mismatch of only 0.2 millimeters, which allows your locally-owned casting manufacturer in Erie, Pennsylvania, to compete with top-performing foundries internationally. Thanks in part to the DISA MATCH 20/24 Molding System’s simple design and minimal moving parts, maintenance is drastically reduced, and the machine can run continuously without interruptions. In addition to all the other advanced features listed earlier in this article, the DISA comes with an in-chamber parting spray system to prevent sand from sticking to the pattern plate.
Click here to view the DISA MATCH 20/24 Specs
This spray system reduces the parting fluid usage and airborne parting fluid. Easy-to-change cope and drag wear plates allow for high-speed pattern changes. A centrally-controlled database (known as CIM) within the DISA MATCH allows it to store up to 30,000 different pattern sets, which include the names of the patterns, the type of casting, the customer details, and all the pattern parameters needed for the part. The CIM collects real-time data, which simplifies and speeds up the troubleshooting of defects. Ultimately, the CIM lowers scrap, reduces downtime, and boosts production. All the options and features included with a DISA MATCH allow for flexible, clean operations. Machine Operators now have increased workspace that is not only cleaner, but also quieter. The new automatic molding system is matched up to our revamped Summit Mold Handling System.
FAQs About Choosing a Casting Manufacturer with DISA Match
What makes a casting manufacturer like Erie Bronze more reliable for tight-tolerance projects with a DISA Match 20/24 versus other equipment?
Erie Bronze can achieve a maximum mismatch of only 0.2 millimeters thanks to the DISA Match system’s advanced blow and squeeze system, rigid tooling support, and in-chamber parting spray. This technology provides our in-house engineers and our customers with confidence that all parts will demonstrate dimensional repeatability across both short-run and high-volume production runs.
How does the DISA Match 20/24 improve lead times for bronze and aluminum castings?
With an automatic Core Setter and a rapid pattern-change capability, the DISA Match dramatically increases throughput up to 145 cored molds per hour. This results in faster lead times without sacrificing the quality of cast parts, which is significantly important for OEMs that need quick turnaround times on parts that must adhere to rigid quality standards.
Can the DISA Match 20/24 handle part designs with complex shapes, geometries, or deep cores?
Absolutely! With horizontal blowing and an advanced sand-blow system, the DISA Match can effectively fill deep pockets and complex cavities in your part design without the need for additional steps or equipment.
Why should I choose Erie Bronze & Aluminum for DISA-based casting projects?
Erie Bronze & Aluminum is a top sand casting manufacturer and pairs the tremendous capabilities of the new DISA Match 20/24 Automated Green Sand Molding Machine with over a century of metallurgical expertise, certified quality systems, and experience producing challenging parts for demanding applications within the oil and gas, aerospace, defense, and other industrial markets.
Our Future As A Casting Manufacturer: Cost Saving & Production Efficiency
We are truly excited about the growth adding the DISA Match 20/24 Automated Green Sand Molding Machine will bring to our company, as well as to our customers and community. Erie Bronze & Aluminum Company was founded in 1907 and was the first US-based foundry to utilize the newest metal treatment and gas analyzing technology developed in Europe. The Foundry Degassing Unit allows us to control the real-time hydrogen levels of our aluminum alloys directly within the molten metal. A few advantages of this automated process include improved surface finish, reduction of hard inclusions, increased tensile strength, and reproducible results.
Erie Bronze & Aluminum is a small business with over twenty employees that produces both bronze and aluminum castings for the United States Government. We follow a strict quality system per MIL-I-45208 standards. Examples of previous work include bronze guides for catapult systems, aluminum labyrinth seals for Navy compressors, bronze extension fittings, cylinder heads and bodies, and various bronze and aluminum castings for Naval Sea systems.
Now that you’ve read this article, you have learned how our locally-owned Erie Bronze & Aluminum Company upgraded our automatic molding machine to be more user-friendly and efficient, while keeping us on top of the leading nonferrous foundries in the country. Ready to learn more about us? Browse our website for our current capabilities and services.
