SanCasT

Transcript (Download)

We wanted to build a foundry that would fit into the land.

No overhead power lines, no smoke.

We examined what a foundry should be able to do and then went out and built one from scratch.

We designed operating procedures to ensure that our castings would meet the very tightest specifications.

My job is to saw a small piece out of a finished casting so we can work with it in the This core machine is fully automatic.

I check each piece as I unload the machine.

The sand has to be just right to make a good casting with a nice finish.

I test it for consistency and permeability.

The sand is fed to this machine that automatically makes the mold for the casting.

I put the cores in the mold to form the hollow spaces inside the casting.

After the specimen is embedded in plastic, I polish it so we can I weigh the pig iron and scrap.

They tell me these rail croppings are top grade.

To double check the weight, we get a print out of every charge for the permanent record.

Then the scrap goes into the charging bucket.

My job is to transfer the molten iron to the molds.

After pouring the molds, I keep the cover closed so the ladle will stay up to temperature.

When the iron is up to temperature, I take the slag out of the furnace.

With these coreless induction furnaces, we know exactly what to expect.

The sample we're here is a double check.

We use this spectrometer to measure the percentage of each alloy in a sample.

To determine the exact amount of sulfur and carbon, we use a LECO gas tester.

Well, before tapping the furnace, I have to make sure the ladle is clean.

And I also check the color of the inside of the ladle to see that it's up to temperature.

All right, let's pour.

Usually there's always a little slag left in the ladle, so I take it out before we pour.

To avoid the need for heat treating, the cooling rate must be accurately controlled.

Sandcast holds patent on this process.

After the castings are removed from the molds, the cooling rate is accelerated to get the microstructure we want.

The castings are then shock blasted and grounded to customer specification.

Our foundry has lab equipment that is set up to do both static and dynamic fatigue testing on anything we make.

The sample is etched in an acid bath.

This makes the grain stand out.

What's up? What's going on? The machine came down and crushed the mold.

Looks okay down here.

Check the control panel.

Here's a loose wire.

It seems to work now.

I examined the sample to make sure the microstructure meets spec.

This one is perfect.

Identifier

F.2004-02-0044

Date Of Production

circa 1981

Abstract

Industrial film about casting follows the process of making castings from start to finish at SanCast Inc., melting down scrap into glowing liquid iron, pouring molds, and testing samples in the lab. The narrator highlights stringent testing procedures taken to meet standards. Most shots are quick cuts of still or handheld shots following action with CU of details from various angles. Factory workers are in most shots conducting the following activities in the SanCast Inc. foundry.

Log

00:11 - Var exterior SanCast, Inc. building
00:21 - interior shots of foundry, workers and assembly lines pouring metals; interior worker with casting machinery, working in lab
01:15 - workers with fully automatic core machine, CU details; testing consistency of sand, workers filling and checking casting mold
02:11 - polishing specimen embedded in plastic for testing; worker weighing and moving scrap, magnet on crane moves scrap metal, after weighed, goes into charging bucket
03:14 - charging bucket melts down scrap; transferring molten iron to molds in ladle; iron brought to temp, worker takes slag out of furnace, takes samples
04:30 - spectrometer in lab, measures each alloy in sample; clean ladle, taps furnace, checks temperature, pours iron into mold and removes ladle
06:02 - slow motion, CU pouring iron; cooling line, removed from molds
07:06 - castings shot blasted and ground to customer's specifications; lab equipment for static and fatigue testing; sample etched in acid bath to make grain stand out
08:06 - alarm going off, machine crushed the mold, workers run to check out problem; examining sample under microscope
08:57-09:06 - exterior SanCast Inc. building

Run Time

0:11:07

Format

16mm

Extent

350 feet

Color

Color

Sound

Optical

Reel/Tape Number

1/1

Has Been Digitized?

Yes

Language Of Materials

English

Element

Answer Print

Genre

Industrial
Sponsored

Form

Advertisements

Subject

Industry
Factories

Related Collections

Jack Behrend Collection

Related Places

North America ➜ United States ➜ Ohio ➜ Coshocton

Sponsor/client

SanCast

Main Credits

Odyssey Productions (is production company)

Behrend, Jack (is producer)

Additional Credits

Odyssey Productions (is contributor)

Behrend, Jack (is contributor)

Burrit, Chris (is cinematographer)

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