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Melt deck at an iron foundry with ladles and charge material

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Every process your part needs, through one rep.

Each plant in our network does a few things exceptionally well. Here is what the network covers, process by process, with the real numbers buyers ask about.

Automated pouring of molten iron into sand molds Foundry operator monitoring a ladle pour Rotary cooling drum and shakeout conveyors in a foundry

Ferrous foundry

Iron castings

Vertically integrated gray and ductile iron foundries with automated molding lines, in-house core rooms and robotic finishing. Electric-melt iron is available for buyers who report on carbon.

  • MaterialsGray iron G1800 to G4000, ductile D4018 to D7003, austempered ductile (ADI), high-silicon moly for heat resistance
  • Part weight1 to 100 lb castings, up to 200 lb machined
  • MoldingAutomated vertical and horizontal green sand lines, cold box cores
  • Capacity500,000+ tons per year across the network
  • SpecsSAE J434, ASTM A536, DIN EN 1563, JIS G 5502, ISO 1083 and custom chemistries
  • Typical partsKnuckles, carriers, differential cases, manifolds, valve and pump bodies, brackets, brake drums, bearing caps
Aluminum die casting plant floor with finished parts in baskets Two aluminum die cast oil pans Aluminum die cast brackets and covers

Non-ferrous foundry

Aluminum castings

High pressure die casting with in-house machining and assembly, plus access to sand, permanent mold, low-pressure and investment casting when the geometry or volume calls for it.

  • HPDCDie cast machines from 250 to 850 tons
  • Other processesGreen sand, permanent mold, low-pressure permanent mold, investment, shell, no-bake, plaster
  • AlloysA360, A380, A383, ADC12, 319, A356, 357, 390, 413, Silafont 36
  • Typical partsEngine and cab mount brackets, oil pans, front and PTU covers, EV drive module and battery tray brackets
Long machined aluminum extrusion rail Multi-cell aluminum extrusions cut for crush boxes Chrome and black forged tow hooks

Wrought metal

Forgings & extrusions

Closed-die forgings and large, complex aluminum extrusions that are sawed, machined and inspected in the same plant. Long-part machining and touchless scanning are a specialty.

  • ExtrusionLarge-format 6000 series profiles: rails, rockers, longitudinals, battery frame members
  • ForgingClosed-die carbon and alloy steel and aluminum forgings
  • FinishingSaw, CNC machine, deburr, wash and touchless 3D scan for straightness and profile
  • Typical partsSiderails, crush boxes, tow hooks, shafts, frame reinforcements
Collaborative robot loading a CNC lathe Robot tending a CNC lathe inside a guarded cell Vertical machining center with tooling staged

Machining

CNC machining

This is where most castings become usable parts. Our machining partners run robot-tended cells around the clock and carry a finished-goods buffer, so a hiccup on their side doesn't stop your line.

  • Equipment350+ CNC machines: horizontal and vertical machining centers, high-speed mills, CNC lathes
  • AutomationRobotic and cobot machine tending, automated load and unload cells
  • Operation24/7 operation at core plants with surge capacity and a finished-goods buffer
  • Sweet spotHard-to-machine iron, long aluminum extrusions, high-mix and high-volume runs
  • ToolingIn-house fixture, gauge and tooling design and build
Automated leak test cell for a cast elbow Torque-controlled assembly station with digital controller Laser marking station on a parts conveyor

Finishing

Assembly & test

Parts ship as finished sub-assemblies when that saves you a step. Every station is error-proofed and every part can carry its own traceability mark.

  • AssemblyMulti-station assembly, stud and bushing press, rubber-to-metal mount assemblies
  • TestLeak test, torque monitoring and audit
  • FinishingAqueous wash, rust preventative, cleanliness testing
  • TraceabilityLaser marking with lot, date and serial data
Bent steel tubes in a row Mechanical stamping presses on a shop floor Cast iron bearing caps with studs

Other processes

Powder metal, tubing & stampings

For the parts that don't start as a casting. Order sizes run from 500 pieces to more than a million.

  • Powder metal12 to 250 ton multi-level presses, belt sintering with sinter hardening
  • PM materialsIron-carbon, iron-copper, iron-nickel steels, stainless, bronze, brass, copper infiltrated, magnetic
  • PM partsGears and sprockets, bearings and bushings, counterweights, spacers, precision washers
  • TubingRound steel tube to SAE J403, cut, bent and formed for seat and structural parts
  • StampingStamped brackets and components through partner stampers

Engineering & launch

Fix it on the print, not on the floor.

The plant's engineers review your part before the quote, not after the tool is cut. Casting simulation catches shrink and porosity while changes are still cheap.

Solidification simulation of an exhaust manifold casting Mold filling temperature simulation of a casting and gating Printed prototype parts beside cast and machined versions
  • DFMDesign for manufacturability review with every quote
  • SimulationMAGMASOFT and EKK mold filling and solidification modeling
  • CAD / CAMSiemens NX part and print design, Cimatron fixture and mold design
  • PrototypesRapid prototypes in as little as one to two weeks, in multiple materials at once
  • LaunchCompressed launches and troubled-supplier takeovers, PO to production in as little as 12 weeks

Quality

Measured, documented, traceable.

Automotive quality systems across the network, with metrology to match. Incoming, in-process and final inspection on every program.

IATF 16949:2016ISO 9001:2015ISO 14001:2015ITAR registeredPPAP / APQP
Structured light 3D scanner with a part model on screen
3D scanningStructured light and laser scan to CAD
Operator at a real-time X-ray inspection system for castings
X-ray inspectionReal-time radiography for porosity
Portable optical tracker for 3D measurement
Portable CMMOptical tracking for large parts
Precision length measuring gauge with digital readout
GaugingCalibrated length and bore gauges
Surface profile and form measuring gauge
Surface & formProfile, roughness and contour
Industrial parts washer loaded with machined housings
CleanlinessWash and cleanliness verification

Materials reference

Grades we quote most.

FamilyGradesProcessesNotes
Ductile ironD4018, D4512, D5506, D7003, FCD 450/500, ADIGreen sand, shellSafety-critical chassis and suspension
Gray ironG1800 to G4000Green sandBrake, housings, pump bodies
HiSiMo ironHigh-silicon molybdenumGreen sandTurbo housings and exhaust heat
AluminumA360, A380, A383, ADC12, 319, A356, 357, 390, 413, Silafont 36, 6000 seriesHPDC, permanent mold, sand, extrusionLightweight brackets, covers, structure
SteelCarbon, alloy and stainless; SAE J403 tubeForging, investment casting, tube, stampingShafts, hooks, tube structures
Powder metalFe-C, Fe-Cu, Fe-Ni, sinter-hardened, stainless, bronzePress and sinterGears, bushings, counterweights

Have a print on your desk?

Send the package and the annual volume. We'll tell you quickly whether our network is a fit and which plant should quote it.

Send an RFQmglucchese@trinitycompgroup.com