Casting Inspections - Balancing the Cost of Quality

October 7th, 2021

What is the cost of quality? Casting inspections are performed to confirm the manufacturer has met the purchaser’s requirements. However, imposing unnecessary quality requirements can drive up cost, increase production time and scrap good parts.

Castings improvement through interactive engineering

July 23rd, 2021

Working with your casting manufacturer’s engineering team early on in the manufacturing process – ideally, prior to creating tooling – can improve the performance of your casting. Foundry engineers can advise your in-house engineers on the best process and material to meet your performance goals. Here’s how engaging foundry engineers early on can get you the best finished casting.

Understanding Steel Casting Failures

May 26th, 2021

Why do steel castings fail? Hint: “Product defect” is not the number one answer. For an in-depth, technical discussion on why castings fail, view Raymond Monroe’s webinar, “Understanding Steel Castings Failures." Raymond, executive vice president of Steel Founders’ Society of America (SFSA), has graciously given Badger Alloys permission to share this content.

Solidification Analysis Optimizes Castability

April 28th, 2021

Whether you are troubleshooting an issue with an existing casting or working to avoid problems altogether on your first run of a new part, solidification analysis is a valuable exercise. By using Magmasoft to simulate the casting process, our engineering team can identify possible issues and control variables like metal temperature, gate and riser sizes, and even sand types to improve the solidification process in the digital space before the mold is ever made.

Emergency Breakdowns – How Badger Alloys can get you back to business quickly

March 25th, 2021

Whether caused by flooding, power outages, fires or a pandemic, emergency breakdowns can be devastating to your business. This past year has shown us the depth of extreme situations that can shut down manufacturing. At Badger Alloys, we are uniquely positioned to prioritize our customers in emergency breakdown situations. As a full-service castings manufacturer, we are able to expedite urgent projects to get you back to business quickly.

Prototypes – high-quality castings with quick turnaround

February 3rd, 2021

With mounting pressures to decrease casting production time while keeping costs low, casting engineers can find prototypes to be an ideal solution. Prototyping can be effective for one-off parts, for new parts that require design refinement, or in situations where you need a few pre-production parts quickly as you ramp up for full production.

Improve the cost of quality with on-site machining

January 4th, 2021

If you seek to improve the quality of your castings and lower the cost of quality, consider having your machining performed by your castings manufacturer. When a castings supplier is asked to deliver un-machined castings, they are prevented from identifying and resolving issues that can only be discovered during the machining process. Castings suppliers that are responsible for the machined castings have the knowledge, incentive and tools necessary to provide the most efficient solution.

3D Scanning Can be a Solution for Worn/Obsolete Equipment or Parts

August 25th, 2020

If your worn part needs to be replaced and is obsolete, and/or the pattern equipment is beyond its useful life or otherwise unavailable, you need to find a quick solution to maintain or resume production. New technologies have made reverse engineering an affordable option for refurbishing legacy parts in a relatively short amount of time, even when drawings or models are not available.

Badger Alloys Welcomes New Quality Engineer

July 22nd, 2020

Bret Kohler, CSSBB, has joined the company as Quality Engineer. He is an experienced industrial and mechanical engineer who has focused his career on process improvement through Six Sigma and other root cause analysis tools to improve internal and external quality. In his role at Badger Alloys he will investigate the systematic processes throughout the foundry, identifying opportunities for improvement, researching best practices and implementing solutions.

Badger Alloys Welcomes New Operations Manager

April 16th, 2020

Richard Flahive has joined Badger Alloys as Operations Manager.

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