Case Study

Thomas Dudley Ltd

In-mould Magnesium Ferro Silicon alloy and Advanced Thermal Analysis (ATAS)

In 2010, our new DISA line was

officially unveiled as part of our

ambitious plans for the future.

Asmet helped us install an

inmould nodularisation process

using an inmould Magnesium Ferro

Silicon Alloy that guarantees both

consistent and high quality levels.

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Thomas Dudley Limited - In-mould Magnesium Ferro Silicon alloy and Advanced Thermal Analysis (ATAS)

Founded in 1920, the iron foundry at Thomas Dudley Limited manufactures castings in Flake and Nodular (Ductile) Irons. It supplies merchants, contractors and the utility industries with the UK's largest range of ferrous castings and also works closely with customers nationwide to manufacture ferrous castings to their own specifications.

It is a quality assured organisation, having gained certification in:
• OHSAS 18001 (Health & Safety Management Systems)
• BS EN ISO 14001 (Environmental Management Systems)
• BS EN ISO 9001 (Quality Management Systems)

At Thomas Dudley, they understand the need for manufacturers to work with casting suppliers who can produce quality assured cast iron components. They also expect their suppliers to work closely with them to help them achieve their customer expectations. Here's how Asmet has helped them to achieve success in their business.

Asmet Case Study - ATAS
We have worked closely with Asmet, and they have been a key supplier of foundry raw materials (Pig Iron and Ferro Alloys) as well as technical support over many years. In 2010, our new DISA line was officially unveiled as part of our ambitious plans for the future. Asmet helped us to install an inmould nodularisation process using a product that would guarantee both consistent and high levels of quality.

Trials were undertaken using Asmet material, which is now established as our first choice in-mould Magnesium Ferro Silicon alloy. During this period the foundry management team recognised the metal control could be improved and suggested that Asmet assist by investigating using the Advanced Thermal Analysis System (ATAS), designed and manufactured by Novacast Systems AB, Sweden.

Over a number of weeks a series of investigations were undertaken by Asmet, utilising their portable ATAS equipment to review metal control at the furnaces and moulding lines. This work helped us to realise potential areas for improvement, and how ATAS could be installed as effective shop floor process control. In July 2010 Thomas Dudley purchased the ATAS process.

With the help of Asmet, ATAS is now fully integrated into our process control procedures. The process has allowed Thomas Dudley to produce iron to tight limits and low metallurgical variation. ATAS not only allows close control of metal chemistry but also enables monitoring of charge material quality. Additives can be assessed for effectiveness and suitability for our process. Variations in nucleation levels and precipitation of graphite can be measured. ATAS offers a degree of accuracy that is beyond analysis or CEL, ATAS provides assured repeatability and material integrity.

Consequently our mechanical properties are comfortably met and risk for shrinkage defects and carbide formation reduced. In turn this has enabled a high degree of confidence in the integrity and machineability of our product.

With the help of Asmet our capabilities can now meet and exceed customer's expectations with a quality assured casting service.