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Seilkop Industries, Inc.

Casting of an Exhaust Gas Recirculation Duct & Air Intake ManifoldS

At Epcor Foundry, a division of Seilkop Industries, Inc.,, we offer precision aluminum castings and casting design services which help our customers to develop high strength, economical castings. The project highlighted here was a redesign casting project for a tier one automotive supplier in the Southeast.

Their original design would have required a supplier to the truck industry, 15 cores, and would have been very costly to cast. We worked with them to redesign the part with a single core without affecting the performance of the part, this decreased the cost of the part tenfold. The 6” by 4” casting is composed of 356 aluminum, and cast utilizing our DISA Match 130 and Roberts Sinto FBO #3 20x24” high speed mold machines, this capability allowed us to meet tolerances of ±.010”. Quality control is maintained through dimensional, inspections as well as ball and flow checking. We redesigned this high volume production part and supplied it within budget and on time.

We currently cast approximately 185,000 of these parts annually, with a turnaround time of 10 weeks. For more information about this exhaust gas duct and air intake manifold project, see the table below, or contact us directly.

Epcor Foundry

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Highlights of this Exhaust Duct & Air Intake Manifold Project

Product Name
Manifolds and EGR Ducts
Product Description
This product is composed of exhaust gas recirculation ducts and air intake manifolds used on car engines.
Casting Capabilities Applied/Processes
Primary:
Casting
De-Coring
Automated Trim Cell
Secondary:
Shot Blasting
Packing
Equipment Used to Manufacture Part
DISA Match 130 & Roberts Sinto FBO #3 20x24" High speed mold machines
Overall Part Dimensions
6" x 4"
Tightest Tolerances
+/- 0.010"
Material Used
356 Aluminum
Material Finish
Color: Silver
In Process Testing/Inspection Performed
Dimensional Inspection, Ball Checking, Flow Checking
Industry for Use
Automotive Industry
Volume
185,000
Delivery/Turnaround Time
10 Weeks
Delivery Location
Southeast
Standards Met
Customer Specifications, 2D CAD Drawing

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