Ellwood Engineered Castings

ELLWOOD ENGINEERED CASTING
Hubbard, OH
a DIVISION OF Ellwood Group, Inc.
Ellwood Group, Inc.
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Celebrating 102 Years – Since 1910
Family-Owned – 4th Generation of Leadership
Sales in excess of $1 billion USD
Debt-free Organic and Acquisition-based Growth
2,250 employees in USA (PA,OH,MI,TX) and Canada
Vertically Integrated – Market Facing Divisions
• Steelmaking
• Forging
• Heat Treatment
• Machining
• Casting
• Heavy Metallurgical Section – Highly Engineered Products
• Preferred Supplier to Global Customer-Base
Ellwood Group Inc
EGI
Ellwood City, PA
MELTING
CASTING
EQS
New Castle, PA
Ingot
ENS
Irvine, PA
Ingot
EEC
Hubbard, OH
Iron Castings
FORGING
ECF
Ellwood City, New
Castle, Corry, PA
Open Die
ETF - H
Houston, TX
Closed Die
ETF – N
Navasota, TX
Closed Die
MACHINING
ENF
Irvine, Warren, PA
Finish & Semi-Finish
ETM
Titusville, PA
ECG
Finish Machining
EAC
Rural Hall , NC
Closed Die
ECM
Hermitage, PA
Repair Shop
ENC
Irvine, PA
Closed Die - CGF
Crankshafts
ENC
Irvine, PA
Finish Machine
Cleveland, OH
Closed Die – CGF
Crankshafts
ENCS
Hermitage, PA
Repair Shop
STEEL
DISTRIBUTION
ESS
New Castle, PA
UNISTEEL
Detroit, MI
Walter Metals
Hudson, OH
Ellwood
Specialty
Metals
LaSalle, Ont
OTHER
EMT
Ellwood City. PA
Ellwood Quality Steels
Forging Quality Ingot
EQS
Ellwood City Forge
EEC
Open-Die Forging
ECF
ECG
Ellwood Crankshaft Group
Open & Closed-Die Crankshafts
ESS
ENF
ETF
Ellwood Specialty Steel
Die Steel Distribution
Ellwood Texas Forge
Closed-Die Forging
Ellwood National Forge
Finish Machine
Long Products - Hollows
EGI Markets Served
Marine/ Shipbuilding
4%
Other
3%
Machinery
3%
Infrastructure &
Construction
3%
Metal Manufacturing
4%
Power Gen
23%
Aerospace/ Commercial
4%
Power Transmission
5%
Automotive
5%
Oil & Gas
22%
Railroad
5%
Mining
6%
Military
13%
EGI Growth – 1984 to 2013 (Projected)
Ellwood Engineered Castings
Highly Engineered Castings
In addition to being the largest ingot mold supplier in
North America, EEC produces high-quality engineered
castings for industries in Power Generation, Mining
Equipment, Dies, Machine Tools, Heavy Construction,
Fluid Transfer & Wind Energy. The castings for these
markets are either high grade gray iron or ductile iron,
which exhibits high strength as well as good toughness
and fatigue strength.
Gray Iron Castings – 2 to 145MT (160T)
Nodular Iron – 2 to 72 MT (80T)
Melt Shop Capabilities
Three 55 T (50 M/T) Induction Furnaces
with charge preheater
Produce Gray & Ductile Iron
Melt Capacity of 10,000 T (9,000MT )/month
Mold Production
Sand system - 1 Walco and 1 Didion are supported by a total of 9
continuous mixers, which in total are capable of mixing &
discharging sand at a rate of 300/2000 lbs (909 kg). per minute. Our
on-site sand reclamation system, which can process up to 90% of
reclaim sand guarantees that sand is conditioned to ensure optimal
properties when blended. Chemically bonded sand molds (Furan).
Pit Molding - Up to 20' ( 6.1 M ) wide x 133' (40.5 M) long x 6'
(1.8 M) deep and 6.4 M (21') wide x 87' (26.5 M) long x 8' (2.4
M) deep
Floor Molding Mobile mixer capable of 1 T (909 kg ) /min.
with 90 T (81.6 M/T ) capacity 21' (6.4M) wide x 26.5 M (87')
long x 2.4M (8') deep
Flask sizes up to 3.7M (12') X 6.7M (22') rectangular and
4.9M (16') square with Mold heights up to 4.3M (14')
Finishing/Inspection Area
Pattern Facility
EEC uses wood, laminate & foam patterns that are typically
sourced from outside pattern shops. EEC performs regular
pattern maintenance & constructs custom blocks for truck, rail &
container shipments.
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Machining Capabilities
 Four planer mills with size capability up to 2,921 mm (115'')
wide x 1,980 mm (78") high x 3,810 mm (150'') long and 82 M/T
(90T)
 Radial drill capable of parts up to 1,220 mm (48") high on
floor and hole size up to 101 mm (4''). Drill up to 1,828 mm (72")
diameter by 3,655 mm (144") high
Power Generation
Hubs
Bases
Transmission
Components
Cast Shafts
Bearing Housings
Spindle
Housings
Gear Box Components
Fossil Fuel Components
Turbine Housings
Machine Tool Components
15‘ (4,600mm)
28.4T(25.8MT)
Plates Tables
Segment 23’ (7M)
Bases
Press Beds
Press Crowns
Column
12’ (3,700 mm)
11.2T (10.1 MT)
Columns
Fluid Handling
Discs
Suction Cover
5.3T (4.8MT)
Valve Bodies
Housings
13.8T (12.5MT) 10.7T (9.7MT)
Mining/ Pulverizing - Material Crushing
Segment Liners
Grinding Mill Head
Pulverizing
Base
Forming Die
Grinding
Mill Trunnion
EEC Engineering
 MAGMASOFT
Casting Simulation Software, network license
 SolidWorks
3 Dimensional Design Software, network licensed
 AutoCAD 3D
3 seats
 F.M.E.A. (Failure Mode & Effects Analysis) and
APQP (Advanced Product Quality Planning) Training
Kent State University
Material Specifications
EEC Grade
ASTM
DIN 1693
DIN EN 1563
UK
new BS
Germany
W.-Nr.
France AFNOR
1003
A48, class 20 B
GG 10
Grade 100
0.601
Ft 10 D
1010
A48, class 25 B
GG 15
Grade 150
0.6015
Ft 15 D
1238
A48, class 30 B
GG 20
Grade 200
0.602
Ft 20 D
1239
A48, class 35 B
1340
A48, class 40 B
Grade 250
0.6025
Ft 25 D
EN-GJS-500-7U
500/7
0.705
GS 500-7
EN-GJS-450-10
450/10
3040
Grade 220
GG 25
GGG 50
3245
3345
A536, 65-45-12
GGG 40
EN-GJS-400-15
420-12
0.704
FGS 400-12
3346
A536, 80-55-06
GGG 60
EN-GJS-600-3U
600/3
0.706
FGS 600-3
3338
A536, 80-55-06
GGG 60
EN-GJS-600-3U
600/3
0.706
FGS 600-3
3145
A536, 60-40-18
GGG 40.3
LG
370/17
0.7043
FGS 370-17
Additional CUSTOM MATERIAL SPECIFICATIONS available on request
NDT Testing Equipment
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Ultrasonic (UT)-Krautkramer USN 58L w/DGS software
Magnetic Particle (MT)-Parker Probe Y7
Die Penetrant (PT)-DP51
Visual (VT)-SCRATA Visual Comparator Plates
NDT Certifications
 ASNT Level III
PT (die penetrant)
 ASNT Level III
MT (magnetic particle)
 ASNT Level II
VT (visual)
 EGI Level III
UT (ultra-sonic)
 EEC Level II
UT (ultra-sonic)
 CWI
American Welding Society
Summary of EEC’s Strengths
1. Owned by a billion dollar, debt free, privately held company specializing
in large, heavy section metal parts.
2. EGI’s commitment to EEC:
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20% of annual tonnage goes to Ellwood Quality Steel (vertical integration)
Over $18 million invested in EEC in the last 5 years.
3. Union Free Plant to assure “continuity of supply” along with EGI’s long
term commitment.
4. Excess iron melt capacity and land to grow with customer requirements.
5. Diversity that supports long term survival during market cycles.
6. EEC’s commitment to continuous improvement
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Improved engineering and APQP planning
Improved process controls to reduce variation and cost per ton
Optimize and enhance the assets we have to control fixed costs for better customer
value.
Ellwood Engineered Castings
7158 Hubbard Masury Road
Hubbard, Ohio U.S.A.
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Dan Rhoads - President [email protected] 330-568-3016
Greg Selip – VP Technical Services [email protected] 330-568-3009
Pat Callihan - VP Operations [email protected] 330-568-3034
Brian Connell – Director of Sales [email protected] 330-568-3040
Bob Scarmack - Ingot Mold Sales Mgr. [email protected] 330-568-3022
Tim Morrow – Sales Associate [email protected] 330-586-3046
Ph: 330.534.8668 - Fax: 330.534.0069
Email: [email protected] Web Site: www.ellwoodgroup.com