Knowledge Center
Below is a collection of resources to learn more about BQC Foundry’s practices, from quality to process to certifications and affiliations.
Quality
At BQC Foundry, metal casting quality is not a mere standard—it’s a defining ethos. With each design, melt, and mold, our commitment shines, showcasing a mastery over casting techniques and foundry processes.
- In-depth Foundry Processes: Beyond just casting molten metal, our detailed processes embrace global metal casting best practices. We’re always on the leading edge, setting the pace in the casting industry.
- Pioneering in Casting Innovations: By incorporating advanced metal casting technologies and methodologies, we’re meeting industry benchmarks and setting them.
- Upholding International Standards: Our affiliations are more than badges—they’re a testament to our commitment to global metal casting standards. Dive into our journey of excellence and understand what sets BQC Foundry apart in the metal casting industry.
Non-Destructive Testing
Through advanced Non-Destructive Testing (NDT) practices tailored to various Military, Aerospace, and commercial specifications, we meticulously analyze our castings, ensuring they stand tall on integrity and precision.
- Liquid Penetrant Testing: Leveraging the Fluorescent Dye Penetrant (Water Washable Type I, Method A, Sensitivity Level I), we evaluate the integrity of both non-magnetic and ferromagnetic parts. By diving deep into surface and sub-surface assessments, this method helps identify potential inconsistencies. Given the high standards we uphold, BQC Foundry collaborates with external experts to guarantee unparalleled testing precision.
- 3D Technologies: Our 3D scanner is adept at capturing intricate details, internal features, and specific part characteristics. It meticulously records each point through laser reflection triangulation, generating a detailed 3D rendering of the object. Be it CAD Design, 3D Modeling, or Laser Scanning, our commitment to precision remains consistent. We partner with specialized experts, ensuring that the 3D analysis of our metal castings remains top-tier.
- Radiography/X-Ray: To further boost our quality assurance, we employ digital & film radiography. This sophisticated technique detects discontinuities in our aluminum sand castings, reinforcing the structural and mechanical criteria set by our clients. Once again, our insistence on nothing short of the best compels us to collaborate with certified radiography labs.
Every testing method, every partner, and every protocol at BQC Foundry is chosen with one goal: Delivering metal castings that exemplify perfection and match the exacting standards of today’s demanding industries.
Chemical & physical Testing
Each BQC Foundry metal casting is a testament to careful crafting. From the purity of the metal to the molding sand’s integrity, our rigorous testing mechanisms dissect every facet.
- Hydrogen Porosity Detection and Mitigation: Every batch of aluminum undergoes rotary de-gassing followed by a specific gravity (or density) test before we proceed with casting. This meticulous process ensures that the aluminum’s structural integrity remains uncompromised, enhancing the final casting’s durability and performance.
- Spectrochemical Analysis: Before greenlighting aluminum for production, we validate its chemical composition using Optical Emissions Spectrometry. Every heat undergoes this scrutiny, underscoring our commitment to consistency and ensuring our castings resonate with purity.
- Physical Testing: Our engineering test clearly shows the casting’s resilience. We gather invaluable data on tensile strength, yield, and elongation by subjecting a sample to tension until it reaches its failure point. This test reaffirms whether the cast alloy aligns with the set specification limits, ensuring our castings are robust and reliable.
- Sand Testing: Our commitment to precision extends to the very sand used for molding. Each batch undergoes autonomous tests for essential physical properties. Such diligence prevents significant variances in sand properties during production. Complementing these automated tests, we conduct thorough laboratory analyses both in-house and in collaboration with external vendors.
Quality assurance in metal casting demands precise, consistent, and comprehensive tests. At BQC Foundry, we ensure that every casting mirrors the pinnacle of craftsmanship and scientific rigor.
Process Control: Perfecting the Art of Casting
At BQC Foundry, we recognize that superior metal casting emerges from a blend of craftsmanship and rigorous process controls. Our mechanisms are designed to consistently produce perfection in the casting industry, ensuring each casting reflects our commitment to excellence.
- Shop Cards – The Blueprint of Precision: Born within our advanced ERP system during order entry, shop cards serve as detailed guides for our casting operations. Every function, whether core making, molding, heat treatment, or visual inspection, is directed by its detailed shop card. These cards carry specific instructions, ensuring that every process unfolds with meticulous attention to detail. They’re not just instructions, but our commitment to ensuring consistency and quality control throughout the casting process.
- Final Inspection – The Seal of Casting Quality: No metal casting leaves our foundry without undergoing this pivotal inspection. This is where we ensure that every piece meets and surpasses the revered BQC Foundry standards, reflecting the zenith of metal casting quality.
Harnessing the power of meticulous process controls, BQC Foundry transforms raw materials into metal casting masterpieces, underlining our position as industry leaders in casting quality and precision.
Certifications & Affiliations
ISO 9001:2015: Our ISO 9001:2015 certification, with a scope of registration that covers Sales, Manufacturing, and Distribution of Aluminum Sand Casting Products, reaffirms our dedication to upholding global best practices in quality management.
Conflict Minerals – Section 1502 of the Dodd-Frank Act: Though a privately held entity, BQC Foundry firmly supports Section 1502’s goals and objectives. We understand the significance of transparency regarding “conflict minerals.” While BQC Foundry does not have to adhere to this act, our proactive approach involves a rigorous inquiry into our supply chain. We mandate that our raw material suppliers provide a declaration (CMRT) to verify their compliance, ensuring our castings are ethical and globally responsible. All declarations are available upon request.
California Prop 65: BQC Foundry is fully committed to continually improving our customer service, manufacturing, quality control, and QMS objectives. We aim to meet or exceed all internal and external regulations while exceeding our customer’s expectations. This desire includes providing our customers with products compliant with California’s Proposition 65. Aluminum sand castings found in an as-cast condition are considered articles and, therefore, do not pose a physical hazard or health risk to employees or consumers While these castings are deemed non-hazardous, it’s essential to note that trace chemicals, listed under Prop 65, may be present, albeit unintentionally. For more information, please refer to our Safety Data Sheets.
ITAR Compliant: BQC Foundry’s registration with the International Traffic in Arms Regulations (ITAR) and the DDTC Manufacturer Registration emphasizes our ability to handle defense-related projects, ensuring we operate within the confines of global arms regulations.
American Foundry Society: Our membership with the American Foundry Society showcases our deep-rooted involvement in the broader metal casting community, echoing our commitment to industry growth, learning, and excellence.
Through these affiliations and certifications, BQC Foundry promises and proves our devotion to meeting the highest benchmarks in metal casting.
Safety Data Sheets
In metal casting, safety is paramount, and knowledge is its cornerstone. At BQC Foundry, we prioritize both, providing comprehensive safety data sheets that offer detailed insights into our practices, materials, and processes.
- Transparent Reporting: Every safety data sheet is meticulously detailed, ensuring that stakeholders, from employees to clients, understand our practices’ safety profile.
- Regular Updates: As practices evolve and new information emerges, our safety data sheets are updated to reflect the latest in metal casting safety standards.
- Accessible Insights: We ensure that our data sheets are comprehensive and accessible, ensuring that safety knowledge is available and understandable to all stakeholders.
FAQs
WHY SHOULD I WORK WITH BQC Foundry?
Decisions in metal casting are vital to the success of your projects. Quality, consistency, and reliability are keywords that drive our casting services. Partner with us and leverage our industry-leading expertise, advanced casting techniques, and commitment to excellence. Let’s transform molten metal into your next success story.
We can manufacture castings from several ounces to 50 lbs, with maximum dimensions of 26” X 28”. We can utilize most existing pattern tooling, including aluminum and renboard, and cast iron or aluminum core boxes. The typical lead time is 6-8 weeks. Typically, 3-4 weeks after receipt of pattern tooling. 4-8 weeks, depending on the molding center. You can expect a response within 72 hours. Green diamond sand, a non-silica option, for automatic molding machines. Currently, we specialize in high quality aluminum sand castings. These types of services are available through one of our local partners and we would be happy to provide a recommendation. We prefer SOLIDWORKS (sldprt) but can use most files, including IGES (igs) and STEP (stp). Our sand castings have surface finishes ranging from 250 to 500 microns in accordance with Aluminum Association Standards (AA-CS-E18-92) Don’t see answers to your questions in the list above?DO YOU HAVE ANY SIZE LIMITATIONS?
WHAT TYPES OF PATTERNS AND CORE BOX TOOLING CAN YOU USE?
IF NEW TOOLING IS REQUIRED WHAT IS YOUR NORMAL LEAD TIME?
WHEN CAN I EXPECT TO RECEIVE SAMPLES?
WHAT ARE YOUR USUAL PRODUCTION LEAD TIMES?
WHAT IS THE TURNAROUND TIME ON A REQUEST FOR QUOTE?
WHAT PROCESSES DO YOU USE TO MANUFACTURE CASTINGS?
CAN YOU PROVIDE SECONDARY SERVICES SUCH AS MACHINING, PLATING, PAINT, OR POWDER COATING?
WHAT TYPES OF 3D FILES DO YOU ACCEPT?
WHAT SURFACE FINISHES CAN I EXPECT FROM A SAND CASTING:
