“It’s difficult to make a decent margin in the U.S. just making a casting.
You have to add value.” —Bruce Barron, CEO
do,” he said. “So we asked if we could take a look at it.” Although the part had massive sections with thin ears and
packaging constraints, Barron Industries asked to try making it as a casting. Te final cast design, produced in 17-4 stainless steel, passed the field tests without issue. “Sometimes I wish we just made regular castings,” said
Barron, who is heavily involved in his company’s casting engineering. “But that’s what makes us unique.” Barron Industries’ ties with defense programs have brought
steady work into the facility, but the company is preparing for potentially shaky years ahead. “In 1990, we were close to 80 or 90% automotive,” Barron
said. “Today, we’re 10% automotive, but we’re 70% defense. With all the budget cuts looming or forecast, we need to find other opportunities.” According to Jeff Barron, the company has feelers out
in a few new markets that have potential casting conversion applications. “[Potential defense budget cuts are] why we’re working on
the petroleum and glass industries,” he said. Te petroleum industry uses the high alloy materials in which
Barron Industries feels it specializes. In particular, the company sees drill bits as potential conversions from wrought hogouts. Barron Industries’ aluminum expansion also could facilitate
entry into new markets, although Bruce Barron admits most of the new aluminum casting work currently is in defense.
Adding Capacity Through Production Tracking
Production at Barron Industries is split evenly between aluminum and steel, and much of the casting operations (wax pattern, tree assembly and slurry dipping) are conducted in the same location. In the casting room, the aluminum furnace and preheat oven line one side of the room. Te steel and stainless steel furnaces are on the other side, and the molds are poured in the same area. “The difference comes after the molds are poured and
cooled.” Barron said. Aluminum molds go to an offsite location (Barron
Industries’ original investment casting facility) to be water blasted and return to the main facility for finishing, which is separate from the steel finishing department. The steel and aluminum parts come together again in the machin- ing department. In the compression straightening cell, aluminum parts
that have been T4 heat treated by an outside vendor are put in a die that completely encapsulates the casting. Te die is put into a press that applies 2,000-3,000 tons of pressure for 30-60 seconds. Te resulting part is sized with tighter
January 2012 MODERN CASTING | 27
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