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  Russell Castings
 
Company
Russell Ductile Castings is the result of two successful foundries joining together. The new company currently has 200 employees and a turnover of over £19 million.

Metal Types
Russell Ductile Castings produces the following types of metals:
Ductile Irons (SG Irons)
Grey Irons
Austempered Ductile Irons (ADI)
Alloyed Irons

Casting Weights
Range from: 0.1 kg to 6000 kg

Product Base
Russell Ductile Castings produces castings for Turbines, Transmissions, Oil & Gas Compressors, Earth Moving Equipment, Vacuum Pumps and Machine Tools.

Moulding Equipment: Chemically Bonded
Russell Ductile Castings follows a flow line process of a hand moulded, chemically bonded sand system using 4 PLC controlled sand mixing machines ranging from 12 to 30 tonne per hour flow rate.

One of our moulding lines uses the conventional boxed moulding technique, while another uses a box-less method of production.

Moulding Equipment: Greensand
Facilities include a Hunter for automated Greensand and a BQ3 for mechanised Greensand production. Russell Ductile Castings can facilitate the following mould face area's:
A. 5.4m X 2.4m X 1.5m
B. 7.3m X 1.6m X 1.5m
C. 3.2m X 3.0m X 1.5m

Coremaking Equipment
Shell - up to 0.5 metre
Cold box - up to 0.3 metre
CO2 - up to 0.9 metre

Volumes
Low to medium, maximum flexibility from small batch production ie 10's, 20's, 50's, 100's etc to quantities exceeding 20,000 per year.

Quality approvals
ISO 9001:2000, Lloyds Register of Shipping.

Customer approvals
Rolls Royce, Siemens, General Electric, Timken, SNCF, 600 Lathes, SKF, Cummins, NACCO, JCB, Bosch Rexroth, Kawasaki, Textron, Terex, Caterpillar, Linde, Bombardier Transportation, Balfour Beatty, Edgar Allen, Sab Wabco.

Other Services
3D modelling, with 2D to 3D conversion.
Computer aided and traditional pattern making; prototype and production manufacture; mould filling and solidification modelling; image capturing; non destructive testing; mechanical and chemical certification; heat treatment; chemical cleaning; shot-blasting; surface coating; machining; on-site assembly facility; kan-ban and line-side delivery.

Specialist Products
Austempered Ductile Iron (ADI) high integrity components; hydraulic parts in Ductile and Grey Cast Iron; supply of machined and assembled components to line side; safety critical components to a variety of markets including Railways, Commercial Vehicles, Materials Handling, Petro-Chemical and Construction Equipment. A variety of large castings for use in the quarrying or secondary processing markets.

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