Omaha Steel’s molding process uses the phenolic urethane base resin system. Well-known as the no-bake or air-set process, this resin system offers multiple advantages over other molding methods. The no-bake process used at Omaha Steel produces the highest-quality castings from one pound to 1,000 pounds across a wide variety of alloys and complex designs. Omaha Steel’s new facility features the latest in molding and sand-processing equipment. Our new equipment offers the most up-to-date sand-mixing technology, featuring a smart gate delivery system that combines the exact amount of reclaim and new sand in the mixer. Fluidized sand heaters ensure the sand’s temperature exactly meets your requirements before entering the mixer. Precise temperature control of sand means we achieve the desired work times needed and produce high-quality molds every time. The mass flow meters compensate for temperature and viscosity changes, providing the exact amount of resin and catalyst to the mixers. The result? A coated sand that achieves the optimal properties as designed by Omaha Steel’s engineers. Omaha Steel uses an exceptional compaction system that creates quality molds using a variety of media, including silica sand, zircon, and chromite sand. The combination of these elements achieves the casting quality and finish you require.
Omaha Steel stays focused on using the best resources and equipment. We believe having the latest cutting-edge equipment in our foundry allows us to serve our customers better. By utilizing the latest in sand processing and mixing, Omaha Steel provides customers with the highest standards of quality castings.
Omaha Steel recognizes that the multiple benefits of no-bake/air-set molding lead to higher-quality molds, resulting in superior castings. The dependability for achieving required dimensions, the flexibility to use simple or complex tooling, and the multitude of pattern and sand types makes the no-bake process the best choice for our customers.
Patterns for producing steel castings come in varying degrees of complexity. Whether simple or intricate, the no-bake process is ideal and stands up with precision to the demands of this process. The patterns can be used to produce quality no-bake castings regardless of previous use in green sand, ester-cured, shell, or furan systems. The strength and rigidity of the no-bake process makes it ideal for cores. Using the no-bake process also means compatibility with multiple sand types and curing processes (gas and liquid), boosting quality and productivity.
One key benefit of the no-bake/air-set process is its versatility in usable pattern materials. Patterns constructed of wood, metal, fiberglass, plastic, and even styrofoam give our customers the options required for their short-term and long-term pattern needs. Another key engineering feature with no-bake molding is the ease of use with many of the engineering molding materials, such as exothermic riser sleeves, ceramic gating, and ceramic filters.
