CASE STUDY: Permanent Mold Castings

We supported a leading castings providers of precision Aluminum castings in
aerospace and commercial industries. They were using refractory sheath and
thermocouple in the crucible from another vendor and had issues with the life of the protection
sheath along with accuracy and responsiveness of the temperature reading. Often these
issues will result in more gas/heat and bad batch of molten aluminum in many cases.

Wilcon actually visited them, did Gemba on the floor, performed root cause analysis and
provided a solution not just sheath or thermocouple. Image below depicts one of the issue
where thermocouple was not in contact with the protection sheath. Wilcon’s solution
along with craftsmanship solved the issue for our permanent mold customer.

Problem Statement:

Thermocouple was not showing accurate temperature and slow
response time will result into more than 20 ̊ F difference within crucible height.

Solution by Wilcon Industries:

Wilcon solved the accuracy and response time by understanding the root cause and implanting corrective actions in final solution. We improved the life of protection sheath by implementing ALU Shield and high quality insultation.

Verification of Effectiveness:

After switching to Wilcon’s ALU Shield, the casting supplier has better process control and longer life of their thermocouples.