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Specialty Foundry Completes Melting Expansion

Sept. 21, 2021
Wall Colmonoy’s new induction melting equipment and magnetically screened furnaces raise melting capacity and reduce processing times, with better reliability and reduced downtime.

Specialty alloy and castings manufacturer Wall Colmonoy Ltd. recently completed an estimated $820,000 improvement program at its foundry in Pontardawe, Wales. The project modernized the foundry and reduced its environmental impact while also improving casting efficiency.

The project included new induction melting equipment and magnetically screened furnaces, for greater melting capacity and reduced processing times, with better reliability and less downtime. Better pouring controls were included too, thanks to data-driven monitoring sensors and software. 

The Welsh foundry has investment casting, centrifugal casting, sand casting, and vacuum casting capabilities.

Wall Colmonoy is a materials engineering group that manufactures surfacing and brazing products, castings, and engineered parts used in aerospace, automotive, oil-and-gas, mining, energy, and other industries.

The manufacturer stated the rising demand from European and U.K. customers for its engineered castings and fully machined components – designed to optimize wear, corrosion, abrasion, and heat resistance – prompted the foundry expansion. Other recent updates there have included new, advanced measuring systems; improved machinery, such as the new Hurco five-axis milling machine; and a Desktop Metal shop system for additive manufacturing.

The £600,000 foundry improvement program was partly funded by Welsh and European funding sources, including a £150,000 (est. $205,000) contribution from the Economy Futures Fund.

 “It is very satisfying to successfully complete the project, with a brand new, high-specification foundry,” commented Andrew Williams, project leader. “The investment puts us on the leading edge of cast alloy melting technology and helps us facilitate our drive for innovative growth to meet the increase in global demand for our castings.”