Ontario – Toronto GTA – Georgetown
Corporation
www.alcoa.com
Ontario
Toronto GTA
Georgetown
Corporation
active
A part of Howmet, Georgetown Casting is a major provider of
aluminum castings for the aerospace and
commercial industries. Georgetown Casting has been a part of
Howmet since 1989.
Howmet Georgetown Casting specializes in small, extremely
complex castings. Located
in Georgetown, Ontario, Canada, the plant occupies 36,000 square
feet of manufacturing space and employs more than 100 people.
Producing aluminum castings, using both
the shell and solid mould process, Georgetown Casting has
developed unique capabilities for producing complex cored
castings. Georgetown Casting produces high-volume lots of small
to medium size castings mainly for the commercial aerospace
industries.
Howmet has long been a world leader in the manufacture of
precision super alloy and titanium investment castings,
primarily for jet aircraft and other gas turbine engines. All of
the group members have in-house capabilities, which include heat
treating, chemical analysis, mechanical testing, penetrant and
radiographic inspection, and CAD facilities. Both North
American operations are networked together using the Casting
Excellence programs, resulting in a totally standard set of
capabilities available to all customers. These include bar
coding, EDI, email, advanced shipment notification, on-line
quality manual (available on diskette), and an FTP site for a
more efficient transfer of electronic files.
In its quest for administrative and technical excellence, both operations of the Howmet Casting Group have become ISO 9002 - AS9100
approved. It is a tribute to an extremely dedicated team of
foundry personnel striving to meet all of its customers' needs.
Country of Ownership: Canada
Year Established: 1963
Exporting: Yes
Primary Industry (NAICS): 331529 - Non-Ferrous Foundries (except Die-Casting)
Primary Business Activity: Manufacturer / Processor / Producer
Total Sales ($CDN): $10,000,000 to $24,999,999
Export Sales ($CDN): $500,000 to $999,999
Number of Employees: 125
Products:
Castings, nes, aluminum/al alloy, unfinished, Non ferrous investment castings
Technology:
Technology: The Forming Process
Step 1 : The process begins with production of a one piece
pattern. This pattern is usually made by injecting wax into an
aluminum die. These dies may range from a simple hand operated
single cavity tool to a fully automated multi cavity tool,
depending on quantities and complexity.
Step 2 : Patterns are fastened by the gates to one or more
runners. The runners are attached to the pouring cup. Both are
usually made of wax. Patterns, runners and pouring cup comprise
the cluster or tree, which is needed to produce the ceramic
mold.
Step 3 : The investment shell technique involves dipping the
entire cluster into a ceramic slurry giving the cluster its
initial face coat.
Step 4 : After drying, the cluster is coated again and again
using progressively coarser grades of ceramic material, until a
self-supporting shell has been formed. The shell may run between
3/16 to 5/8 inches thick.
Step 5 : This is a sectioned view of the shell prior to the de-
waxing process.
Step 6 : The coated cluster is placed in a high temperature
furnace or steam autoclave where the pattern melts and runs out
through the gates, runners and pouring cup. This leaves the
foundry with a ceramic shell containing cavities of the casting
shape desired with passages leading to them.
Step 7 : The molds must be fired to burn out the last traces of
pattern material and to attain a certain degree of permeability
before they can be filled with metal. In the case of solid
molds, this heating has to proceed slowly, in a controlled cycle
which stretches over 12 to 18 hours to avoid cracking.
Step 8 : Molten Metal is poured into the fired shell at
temperatures exceeding 1000 degrees Fahrenheit which varies
depending on the type of alloy.
Step 9 : After the poured metal has cooled, the mold material is
removed from the casting cluster using high pressure water. This
image illustrates a complete cluster just after the mold or
outside shell has been removed.
Step 10 : The individual castings are removed from the cluster
and any remaining protrusions left by gates or runners are
removed by grinders. Generally the castings are sand blasted for
a smoother finish. The castings are then ready for secondary
operations.
Sector:
Plant Information: Total Plant Size (Areas sq ft): 36,000
Key / Major Clients: Honeywell - Pratt - Whitney Canada - Woodward Inc. - Raytheon - B. F. Goodrich - Hughes - Litton -
Lockheed Martin
Amey Rob
Clare Bryan
Hack Andreas
Hand Larry
Laing Ted
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