Epcor is your team for fresh thinking. We challenge existing assumptions and then put our technology and processes to succeed where others fail.
Below is another example of our aluminum casting breakthroughs.
OEM automotive company was plagued by housing components that failed due to leakage.
Step 1: We used simulation sofware to correct areas that had been causing problems.
Step 2: Our engineering team designed new tooling to cast a chill into the rotor core – allowing heavy sections to solidify without shrink prorosity.
Epcor eliminated leaking – 100%!
The harsh work environment in the foundry is like no other. It is exactly that demanding environment that has positioned foundries to be on the leading edge of robotic automation. All foundries contend with high temperatures and the inherent issues associated with pouring metal. Robots handle this in a repeatable fashion that makes the foundry more efficient, safer, and unfazed by the heat seen in production.
At Epcor, the benefits for adding robotic automation were considerable:
Robotic automation also provides us with the flexibility to change – as your part requirements change.
Have a question about reshoring aluminum casting work? Allow Epcor to show you our precision craftsmanship, especially for complex and highly cored leak-tight castings, used in several industries including automotive.
As the number of automobiles increases, manufacturers of aluminum parts will be called upon to make more complex high-tech lightweight parts to increase safety and last longer. For this industry, aluminum builds better vehicles. The importance of aluminum in commercial vehicles and cars is increasing due to the many industry advantages. While most people emphasize the lightweight benefits for increasing fuel economy and reducing emissions, we like to also point out that castings made from aluminum can be amazingly complex while also being cost-effective, strong and very durable. Look for more aluminum in each vehicle in the future, including the structure.
Epcor Foundry, a division of Seilkop Industries, Inc., recently announced Jeffrey A. Miller as National Sales Executive, effective immediately.
For the past twenty-three years, Jeff Miller has held key management positions in casting and machining sales and is highly experienced working with our nation’s largest users of automotive and truck parts.
In this position, Miller will be responsible for account management, equipment quotations, and developing metal casting solutions.
“Jeff is a seasoned manufacturing and sales professional focused on developing successful aluminum casting solutions, especially for the transportation and truck industry. We look forward to his contributions and technical expertise to drive our Company’s goals into additional markets. We are pleased to have him onboard in this important position,” said David Seilkop, President of Epcor Foundry.
Miller is a graduate of Bowling Green State University with a bachelor’s degree in business.
American Made, Globally Trusted & Lowest cost
- Epcor Foundry is your low cost U.S. source and proud to be 100% designed, engineered, and manufactured in our Cincinnati, Ohio production facility.
American Made. Globally Trusted
- the automotive industry's most widely used international standards for quality management.
Epcor's prototyping services lead to substantial cost savings. Read about our process to reduce prototype costs.
Read about Epcor's Preventative Maintenance (PM) program that focuses on prevention over detection.
Read about how Epcor designed a better performing super light and leak-free casting for high performance automobiles.
Read about how Epcor’s automated process control ensures castings are made of the highest quality.
Read about this Tier 1 automotive challenge that Epcor solved with a new gating system which eliminated leaks and scrap.
Epcor Foundry, a division of Seilkop Industries recently installed a combination dry hearth and wet bath aluminum melting furnace from The Schaefer Group.
This gas fired furnace delivers degassed and filtered metal to the casting line – which gives Epcor the cleanest metal possible. The end opposite the dry hearth has a degassing unit and a filter with two electric elements in the ladle well end of the furnace, to maintain temperature stability during production.
"The Schaefer Combination Furnace gives Epcor the ability to produce higher quality parts more efficiently,” said Dave Seilkop, president of Epcor Foundry. “The unique ability of this energy saving combination furnace to also reduce metal loss with cleaner metal makes this an ideal choice for our aluminum part production,” he added. Installing the best equipment means producing better products at less cost for our customers – it's that simple!
Like every “solution,” this one started with a problem. An unnamed foundry supplying exhaust gas recirculation (EGR) valves to an auto parts manufacturer could not fulfill the order, and that buyer urgently needed to find an alternative source for aluminum castings. Epcor Foundries in Cincinnati was awarded the business. Then, Epcor’s challenge was to get the new part into production quickly, avoiding the quality problems that the previous supplier faced.
Epcor used ESI Group’s QuikCast casting simulation software to evaluate the initial mold design. They were able to identify several areas where the simulation showed porosity would be a problem. Engineers ran a series of alternative mold solutions while adding risers to feed molten metal to compensate for shrinkage in critical areas of the mold.
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