If your question is not answered here, please contact our sales department.

FREQUENTLY ASKED QUESTIONS

Pricing & Purchasing

How can I get a quote?


You can request a quote for castings by sending an email to jay@russelloyfoundry.com. Before a part can be priced, we will require a print and a material specification at a minimum. The more information you can send (part weights, estimated annual demand, pictures of existing tooling, etc.) the faster we will be able to process your request. If you have any questions, please feel free to contact us.




How much do castings cost?


The cost of casting varies according to project demands such as:

  • Casting function
  • Dimensions
  • Metal grade
  • Tolerances
  • Finishing / secondary processing requirements
Casting relies on economies of scale, so higher volume production runs will cost less per casting than low volume runs. For detailed information on costs for your project, request a quote at our contact page or email: jay@russelloyfoundry.com




What is the lead time for my order?


Lead time vary based on several factors, including current facility capacity, order volume, complexity of parts and materials required. Our current standard lead time is 14 weeks from receipt of purchase order since iron castings are currently in high demand, but we are flexible and will do everything we can to accomodate. We are continuously working to decrease lead time and increase capacity, and our process is fluid enough that we are able to satisfy urgent needs for customers as they arise.




How can I pay for my order?


Payment by check is our preferred method of payment. When submitting payment by check allow time for transit and processing. Orders ship only after checks have been received, processed and funds deposited. Send checks collect to: 1010 4th Street, P.O. Box, Durant, Iowa, 52747. Another available payment method is electronic funds transfer (EFT): Specify EFT when submitting an order and we will provide bank transfer details.




How much do custom products cost?


All our casting work is custom and priced on a case-by-case basis. Custom castings and moldings have many elements that influence their final cost, including pattern complexity, run size, casting process, material used, and secondary processing required. Consultation with Jay Irwin, President of Russelloy, will help find the most economical combination of these factors to answer your needs. Contact Jay at jay@russelloyfoundry.com.





Process & Production

What is your quality process?


Before production of a part begins, samples are made and verified to be correct to the print. Most customers choose to receive samples before the full production run begins, and we encourage this to ensure you are happy with your parts. Each part we make is inspected at each step by our experienced production team with a final inspection taking place before the parts are approved for shipment. We understand that there may be concerns with quality. Our customer service team will always work with you to address and correct the problem by replacing your parts as quickly as possible to prevent recurrence of the issue.




What other metals do you use?


At this time, we only offer gray and ductile iron castings. However, if your part requires a different metal we have partnerships with foundries that pour steel, stainless steel, ni-hard, ni-resists, aluminum, and bronze.




What is the difference between gray and ductile iron?


There are a few key differences between gray and ductile iron. Gray iron is generally easier to machine, better at dampening vibration, and is less expensive. Gray iron is often used to make manhole covers and machine parts. Ductile iron is stronger and more impact resistant, but more expensive and more difficult to machine. Many ductile iron castings are used to make pump components and gear boxes.




How many lines do you run?


We currently have two green sand lines. The majority of our production is handled on our cope & drag line, which runs our smaller flasks (mainly 24x27 and 30x32), and is well-suited for low-to-medium volume work. Our larger cope & drag machine runs 40x40 flasks, and is used for lower-volume runs of large, complex castings. We also have no-bake molding capability, which allows us to accommodate low-volume orders in flasks sized from 14x16 up to 48x60.




What is your capacity?


Our process facilitates quick changeovers and allows us to accept orders as small as 1 piece. We are one of only a few foundries that specialize in short runs and one-off jobs. Our targeted annual volume for our cope & drag line is 100 – 200 pieces per year. For our larger castings, target annual volume is 10 – 50 molds per year. Our no-bake jobbing floor focuses on running either very small or very large castings, and handles our most complex work. The job floor currently only supports low-volume work, but we are striving improve plant and process to offer greater capacity in the near future.




What are your methods of ramming mold boxes?


Our cope & drag molds are hand-rammed on jolt/squeeze machines which allows high levels of detail while retaining structural integrity. Our no-bake molds are hand-packed and vibrated, making it possible to cast very complex parts. We can also create molds with loose patterns through the use of these techniques.





Machining & Tooling

Do we offer machining or partner with the machine shop?


We do not offer single-source responsibility for machining, but depending on volume, may be able to help with referral to a machine shop that will fit your needs.




Do you make your own tooling?


We have a full pattern shop but focus on repair and maintenance. New patterns are made by one of our affiliated pattern shops.