Sand Casting Process: Below is an example of match plate sand casting, one of several processes used to produce the Dover product line. Additionally, we use investment casting, forging, welding, and machining.
PATTERNS AND DIES
Patterns and Dies: The majority of the Dover product line is produced using patterns and dies.
The first step in producing a pattern or die is engineering and design. Once the design is
approved, a prototype is made, followed by the production of the final pattern or die.
Dover uses hundreds of patterns and dies to produce our expansive product line. Our
patterns and dies are distributed amongst several foundries and forging companies nationwide.
Our entire product line is produced wholly in the United States.
FORGING
Forging: Drop forging is a forging process where a hammer is raised and then "dropped" into the workpiece to deform it according to the shape of the die. Dover utilizes Drop Forging to produce our stainless steel and steel dog bolts.
CASTING
Casting: Dover utilizes two types of casting methods, those being Sand Casting and Investment Casting.
Sand casting involves a match-plate pattern of the desired part that is chosen for production. Sand containing bonding material to maintain shape is packed around the pattern. The pattern is then removed from the bonded sand, leaving a cavity in the mold in the shape of the part. Then, molten liquid metal is poured into the cavity, and the metal solidifies. The sand is then removed through a shakeout process, leaving the desired part.
Investment casting, also known as precision casting, is a process in which a wax pattern is used to shape a disposable ceramic mold. A wax pattern is made in the exact shape of the item to be cast. This pattern is coated with a refractory ceramic material. Once the ceramic material is hardened, it is turned upside-down and heated until the wax melts and drains out. The hardened ceramic shell becomes an expendable investment mold. Molten metal is poured into the mold and is left to cool. The metal casting is then broken from the spent mold, leaving the desired part. Investment casting is used for more precise castings compared to sand casting
WELDING
Welding: Dover utilizes the following welding methods: MIG, Stick, and Spot. These methods are used in the production of our ullage assemblies, strainer baskets, etc.
MACHINING
Machining: Dover utilizes both Conventional (Manual) and CNC (Computerized Numerical Control) machines such as lathes, milling, and drilling. Following every process, parts are inspected and tested for quality and accuracy. Once the parts are approved, we then package the order, and prepare it for shipping to anywhere in the world.
Our comprehensive standard product line is available from stock and ready for same-day shipment.
We also offer customized fabrication of other non-stock products with attention to rapid turn around.
