Our "Core Business" is manufacturing quality sand cores, so you can concentrate on what you do best, pouring castings.
Plus, we maintain strong ties with pattern shops so we can provide customers with any tooling and repairing needs.
Waupaca & Marinette, WI:
Alliance Industries, Inc., Waupaca facility has four distinctive core making processes: Shell, Warm Box, ISOSET and Pep Set. Our Marinette facility offers the Shell Core process. Our core machines and core making capabilities allow us to manufacture cores from ounces to hundreds even thousands of pounds.
Shell cores are made using a resin-coated sand that is blown into heated core machines. The cores cure and become rigid due to the reaction between the resin and heat. The cores are yellow in color and the hollow shell that forms the core gives it its name. Shell cores provide the best cosmetics, shakeout and dimensional tolerance of all the core processes. Shell cores can be stored at high temperatures in humid conditions and have an indefinite shelf life. Our core machines are capable of handling almost any size core box and we offer multiple blends of sand to manufacture cores to fit the unique needs of the foundry.
Warm Box Process
In the Warm Box process the core box is warm when the core sand is introduced. The warmth of the core box initiates curing but does not complete it. The cores finish curing outside the core box and sometimes in a separate dryer. This process allows for faster core production cycles than the Shell Box process. The operating temperature in Warm Box is lower, which can extend the life of the tooling. Warm Box cores have excellent hot and cold tensile strengths.
This very efficient and versatile system brings together ISOSET binders and SO2 gasses to cure the cores. This makes possible the manufacturing of intricate cores at an extremely high rate. Vertical and horizontal parting offers flexibility in core design and is the key to maximizing core production. The result is a dense and dimensionally accurate core, which is easy to shake out. The benefit to the foundry is the ability to produce a casting with hard to fill or thin wall sections with the dimensional tolerances specified.
Pep Set Process- New in 2008
Cores or molds bonded with Pep Set binders produce castings that are sound, gas defect-free, with an excellent surface finish. The Pep Set process is used to produce larger cores and molds but it offers the flexibility to make any size core or mold. The tooling used in the Pep Set process is usually more cost effective than tooling in other core processes. This process enables us to produce core weights from .5 to 2000 pounds.
"We look to Alliance for many of our shell core needs, they actively make sure their quality and delivery are second to none. Their team was instrumental in reducing our material handling scrap through improved packaging."