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70-696: The Consett Iron Company Ltd was an industrial business based in the Consett area of County Durham in the United Kingdom. The company owned coal mines and limestone quarries, and manufactured iron and steel. It was registered on 4 April 1864 as successor to the Derwent & Consett Iron Company Ltd. This in turn was the successor to the Derwent Iron Company , founded in 1840. The company's seven collieries and various coke ovens came into

140-488: A Roots blower (a powerful air pump) that was acquired in 1893. William Jenkins was succeeded by the manager under him, George Ainsworth, who served as general manager from 1851 until his death in 1894. The company initially remained in profit, but its equipment and technology was not updated due to the lack of available space at Consett; a move was considered but rejected. The company did not switch to electrical power as others had and its technology became obsolete. By 1924,

210-407: A foundry (a mile from Consett at Crookhall ) capable of making 150 tons of iron castings per week, and a brickworks capable of making around 12,000 bricks per week. The estate had grown to roughly 2,700 workers' cottages. The company ran a 16-bed infirmary to treat injured workers. The 6,000 workers were paid an average of £5.33 a month. The company continually invested in modern equipment, such as

280-445: A hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Melting is performed in a furnace . Virgin material, external scrap, internal scrap, and alloying elements are used to charge

350-500: A material. Heat treatment techniques include annealing , case-hardening , precipitation strengthening , tempering , and quenching . Although the term "heat treatment" applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. After degating and heat treating, sand or other molding media may remain adhered to

420-430: A mold yields leftover metal — including heads, risers, and sprue (sometimes collectively called sprue) — that can exceed 50% of the metal required to pour a full mold. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus overall melting costs. Heat treating

490-591: A rail link to the town. Consett was part of the North West Durham Parliamentary Constituency , last represented by Richard Holden of the Conservative Party after the 2019 general election . Since 2024 it is part of Blaydon and Consett Parliamentary Constituency, represented by Liz Twist. Before 1983, the town gave its name to its parliamentary constituency: Consett (UK Parliament constituency) . Consett

560-706: A rail link would be located and whether this study would focus on the former Derwent Valley Railway or also include the former route via Birtley . Consett's secondary school is Consett Academy . However, near to Consett in Lanchester is St Bede's Catholic School and Sixth Form College and in Stanley North Durham Academy , which along with Consett Academy is part of the New College Durham Academies Trust (NCDAT) managed by New College Durham . Consett

630-517: A result it relied less on loans to survive business cycles and had lower interest rates when it did borrow. He also provided workers with schools, churches, a park, hospital, and other facilities. He died in 1895. The company's share of the British steel market reached a peak of 7.1% in 1894, falling to 4.2% by 1910. Business historians H.W. Richardson and J.M. Bass praised Jenkins's business judgement and choice of managers. Around 1876, railways around

700-419: A significant number, given the town's industrial legacy. A large area formerly used by Shotley Bridge Hospital was sold to a property developer, which began to build a further 400 homes in 2013–2014. This development has now become the multi-award-winning Woodlands Estate. This has further aided Consett's recovery as a top commuter town due to its convenient location between Durham and Newcastle. Along with

770-424: A single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mold that would otherwise be impossible to achieve. Where the cope and drag separates

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840-426: A steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces. Degassing is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal. Gases can form in metal castings in one of two ways: Hydrogen

910-476: A thousand workers' cottages and 500 acres of land. William Jenkins was Consett Iron Company's general manager from 1869 to 1894. Under his leadership, the company experienced sustained profit for the first time, despite severe fluctuations in market conditions, such as the industrial depression that took place from the late 1870s to the early 1890s. The company retained what at the time were large amounts of capital , rather than distributing money to shareholders. As

980-570: A three-year plan to reduce its workforce by 1600. Alongside the public sector, small and medium-sized businesses now provide jobs in the area. The Phileas Fogg Company (County Durham), with its factory in Consett, were mildly famous for a few years from 1988 for their snack food "Made in Medomsley Road, Consett" television adverts. It is now owned by KP Snacks (originally part of United Biscuits ). The Explorer Group , based in Consett,

1050-401: Is a common contaminant for most cast metals. It forms as a result of material reactions or from water vapor or machine lubricants. If the hydrogen concentration in the melt is too high, the resulting casting will be porous; the hydrogen will exit the molten solution, leaving minuscule air pockets, as the metal cools and solidifies. Porosity often seriously deteriorates the mechanical properties of

1120-416: Is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of

1190-463: Is called the parting line . When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft . The opposite of draft is an undercut where there is part of the pattern under the mold material, making it impossible to remove the pattern without damaging the mold. The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon

1260-567: Is common to paint castings to prevent corrosion and improve visual appeal. Some foundries assemble castings into complete machines or sub-assemblies. Other foundries weld multiple castings or wrought metals together to form a finished product. More and more, finishing processes are being performed by robotic machines, which eliminate the need for a human to physically grind or break parting lines, gating material, or feeders. Machines can reduce risk of injury to workers and lower costs for consumables — while also increasing productivity. They also limit

1330-546: Is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to

1400-498: Is home to the Empire Theatre, one of County Durham's oldest theatres. Recently refurbished, it stages variety acts, plays and a Christmas pantomime. It also screens films at times when there are no live performances. Several pubs have taken names that reflect the town's steel-making past: The Works , The Company , and The Company Row . From Consett's bygone days as a steel town with a strong reliance on rail, next to where

1470-556: Is now home to rival Tesco and Morrisons stores, a string of high street outlets and fast food restaurants. New industrial units are also to be built on the former steel works site, after the Project Genesis Trust secured investment of £358,968 from the Rural Growth Network (RGN) to develop bespoke business premises and offices on part of the site. (The Project Genesis Trust is a body created to regenerate

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1540-532: Is the United Kingdom's second-largest manufacturer of caravans . Elddis Transport Limited is based in the town. Since 2000, there have been several new housing developments on the former steelworks site and surrounding areas. Derwentside College , formerly sited at Park Road, moved to a new campus at Berry Edge in September 2002 and more recently, major retailers have moved in and the site which once made steel for Blackpool Tower and Britain's nuclear submarines

1610-541: Is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates — which are the channels through which the molten metal traveled to reach the component itself. Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches , bandsaws , or ceramic cutoff blades. For some metal types, and with some gating system designs,

1680-557: The Consett Steel Works . British Steel Consett Works was closed in 1980. In 1840 a group of local businessmen led by Jonathan Richardson set up the first of several iron companies in Consett ( County Durham ), the Derwent Iron Company, to quarry and smelt ironstone around the town. The best local ironstone (with the highest iron content) was exhausted soon after, so the company arranged for extensions to

1750-670: The Second World War using lower quality iron ore. It employed about 12,000 workers at that time. In 1947 all of Consett Iron Company's coal mines were nationalised , coming under the control of the National Coal Board . In 1951, the rest of the Consett Iron Company was nationalised by Clement Attlee 's Labour government into the short-lived Iron and Steel Corporation of Great Britain , along with all of Britain's steelworks. The Consett steelworks

1820-426: The 1990s, through Project Genesis, went only some way towards repairing the damage done to the local economy by these closures. Unemployment came down to the national average, but this was partly due to outward migration and economic inactivity due to long-term illness, neither of which were included in the government statistics. In 2011 Durham County Council, which provides a lot of employment for local people, commenced

1890-486: The Department for Transport's Restoring Your Railway Fund , hoping to access up to £50,000 to cover the cost of an initial study into the feasibility of restoring a rail link between Consett and Blaydon. In November 2020 it was announced that the requested funds would be provided for such a study into reinstating a rail service between Consett and Newcastle , although it was unclear where the Consett terminus of such

1960-554: The Derwent Valley's geographical advantage was lost, allowing Sheffield to become the leading centre of the British steel industry. Consett railway station opened in 1896. It remained open for passengers until 1955 and mineral trains continued to pass through the site until 1980 on their way to the steelworks. In November 2020, the Department for Transport approved funding for an initial feasibility study into restoring

2030-572: The amount of material being removed. These steps are done prior to any final machining. After grinding, any surfaces that require tight dimensional control are machined. Many castings are machined in CNC milling centers. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for castings to be used without machining. A few foundries provide other services before shipping cast products to their customers. It

2100-436: The casting surface. Numerous materials may be used to clean cast surfaces, including steel, iron, other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder, and many others. The blasting media is selected to develop the color and reflectance of the cast surface. Terms used to describe this process include cleaning, bead blasting, and sand blasting . Shot peening may be used to further work-harden and finish

2170-423: The casting. To remove any mold remnants, the surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The cleaning media strikes the casting surface at high velocity to dislodge the mold remnants (for example, sand, slag) from

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2240-473: The company began to produce steel in a variety of cross-sections, such as angle (L-section) steel, rolled joists and girders for shipbuilding. For this purpose it created the Angle Mills on a sixteen-acre site, able to produce 1,500 tons of angles, bars and girders per week. By 1889, the Angle Mills site was the largest steel plate factory in the world. In 1892, in addition to steelmaking, the company had

2310-609: The company had share capital of £3,500,000 (£185 million in 2013 terms); it had also issued £1,500,000 (£74 million in 2013 terms) in debenture stock in May 1922. In 1938, the company helped to finance the founding of the New Jarrow Steel Company from the old Palmers Shipbuilding and Iron Company which had collapsed in 1933, leading to the Jarrow March of 1936. The Consett Iron Company continued production during

2380-541: The edge of the Pennines . Its name originates in the Old English Cunecesheafod ( heafod means headland, the meaning of cunec is less clear but is thought to derive from a Brittonic word for "hill"), first recorded in the 13th century. In 1841, it was a village community of only 145, but it was about to become a boom town : below the ground were coking coal and blackband iron ore , and nearby

2450-491: The entire casting manufacturing route. Casting process simulation was initially developed at universities starting from the early ' 70s , mainly in Europe and in the U.S. , and is regarded as the most important innovation in casting technology over the last 50 years. Since the late ' 80s , commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what

2520-433: The facility. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove harmful gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate

2590-536: The former steelworks site). The population soared to 39,000, higher than in the days of steel, and unemployment plummeted. In August 2015, only 420 people were receiving Jobseekers' Allowance, with an official unemployment rate of 1.7 per cent, markedly lower than the rest of County Durham. The wider claimant count of people on out-of-work benefits was 6.3 per cent, half the County Durham average, although it omits those receiving disability benefits, which will be

2660-401: The furnace must be designed for temperatures over 1,600 °C (2,910 °F). The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces ) or coke . The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola , induction furnace, or EAF, while

2730-505: The furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy . Alloying elements are either pure forms of an alloying element, like electrolytic nickel , or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching , forging , or machining . Internal scrap consists of gates , risers , defective castings, and other extraneous metal oddments produced within

2800-466: The highest towns in the United Kingdom. This makes Consett typically at least 2 °C colder than nearby cities such as Durham and Newcastle, and more prone to frost, ice and snow in the winter months. Consett has amenities such as shops, pubs and night clubs that also serve several villages in its immediate surroundings, some such as Shotley Bridge and Blackhill contiguous and some not, for example Moorside and Castleside . The Consett Iron Company

2870-512: The housing developments of the last few years (some still ongoing), there has also been major investment in local amenities, such as a £44-million sports complex in Medomsley Road, near the old sports facilities. This is shared with Consett Academy, which was given a brand new £5.7 million building. In June 2020, the MP for North West Durham, Richard Holden , sponsored a bid to the Ideas Fund of

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2940-444: The iron and steel era a pall of red dust hung over the town, consisting of airborne iron oxide from the steel-making plant. At its peak in the 1960s, the Consett steel works employed 6,000 workers. It was nationalised to become part of the large British Steel Corporation . Although there was intense competition in the 1970s from British firms and from abroad, Consett steelworks remained relatively successful and still profitable even in

3010-403: The largest contributors to the manufacturing recycling movement, melting and recasting millions of tons of scrap metal every year to create new durable goods. Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and reuse sand, which is another form of recycling. In metalworking , casting involves pouring liquid metal into a mold , which contains

3080-644: The local railways, such as the Stockton and Darlington Railway . These allowed it to access new sources of ironstone, including, from 1851 onwards, ore from the Cleveland Ironstone Formation near Eston , Cleveland . By 1857, Consett Iron Company owed the failed Northumberland and Durham District Bank almost a million pounds. It was put up for sale, but an attempted sale to the newly formed Derwent and Consett Iron Company fell through. On 4 April 1864, after operating for several years under

3150-807: The main railway station used to be, is a club named the Station Club, now opposite a health centre. With views over the Derwent Valley, Consett is becoming a popular place to live for commuters from Durham and Tyne and Wear . Consett was the first in the world to have a Salvation Army Corps Band, formed in December 1879 to play on the streets at Christmas. The original four players were Edward Lennox and his bandsmen George Storey, James Simpson and Robert Greenwood. Alphabetical order within sections [REDACTED] Media related to Consett at Wikimedia Commons Foundry Foundries are one of

3220-498: The metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve in gasses. During the tap, final chemistry adjustments are made. Several specialised furnaces are used to heat the metal. Furnaces are refractory-lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces , cupolas , reverberatory , and crucible furnaces. Furnace choice

3290-430: The metal. An efficient way of removing hydrogen from the melt is to bubble a dry, insoluble gas through the melt by purging or agitation. When the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the surface. Chlorine, nitrogen, helium and argon are often used to degas non-ferrous metals. Carbon monoxide is typically used for iron and steel. There are various types of equipment that can measure

3360-488: The national average at the time. The closure marked the end of the Derwent Valley steel heritage, and the decline of Consett as an industrial town. Along with the closure of coal mines, it was also a first step in the decline of all heavy industry in the Derwent Valley. The last steel ingot from the Consett ironworks was made into a cross and is kept at St Mary's Roman Catholic Church, Blackhill. Regeneration in

3430-510: The national average at the time. The sky over Consett, which had long been famous for its thick haze of red iron oxide dust thrown up by the steelworks, cleared as did the cloud of steam typically found around the tall cooling towers and chimneys. Some Consett steel workers took part in the demolition. Almost all traces of the Consett steelworks have been removed. Only the Terra Novalis sculptures (pictured) , made with materials from

3500-450: The national average. A major plan to restructure steel-making in the UK saw light in the mid-1970s, based on concentrating it in five UK coastal locations, to allow easy import of raw materials and export of finished goods. BSC Consett was not one of the locations, despite being serviced by a well-established rail network, producing high-quality boron steel and being in profit in 1980, the year it

3570-458: The ownership of the National Coal Board , when British coal companies were nationalised in 1947. The Consett Iron Company itself was nationalised in 1951, becoming part of the Iron and Steel Corporation of Great Britain . It was denationalised shortly afterwards, then renationalised in 1967. The Consett Iron Company was absorbed into British Steel Corporation in 1967, and the location became known as

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3640-489: The potential for human error and increase repeatability in the quality of grinding. Casting processes simulation uses numerical methods to calculate cast component quality considering mold filling, solidification and cooling, and provides a quantitative prediction of casting mechanical properties, thermal stresses and distortion. Simulation accurately describes a cast component's quality up-front before production starts. The casting rigging can be designed with respect to

3710-400: The presence of hydrogen. Alternatively, the presence of hydrogen can be measured by determining the density of a metal sample. In cases where porosity still remains present after the degassing process, porosity sealing can be accomplished through a process called metal impregnating . In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in

3780-413: The required component properties. This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete casting system also leads to energy , material, and tooling savings. The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making, heat treatment , and finishing. This saves costs along

3850-484: The site, recall past industry. Employment gradually returned to the area in the following decade, with a more diversified industrial base. Consett Consett is a town in the County Durham district, in the ceremonial county of Durham , England, about 14 miles (23 km) south-west of Newcastle upon Tyne . It had a population of 27,394 in 2001 and an estimate of 25,812 in 2019. Consett sits high on

3920-444: The sprue, runners, and gates can be removed by breaking them away from the casting with a sledge hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required to produce castings in

3990-408: The surface. The final step in the process of casting usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape, and surface finish. Removing the remaining gate material, called a gate stub, is usually done using a grinder or sander . These processes are used because their material removal rates are slow enough to control

4060-465: The threat of bankruptcy, a new Consett Iron Company Ltd was formed with capital of £400,000. This was divided into 40,000 shares priced initially at £10 each, with J. Priestman as managing director. Two local members of parliament , Henry Fenwick and John Henderson , were among the directors. It became the owner of 18 blast furnaces . The company had the capacity to produce 80,000 tons of pig iron and 50,000 tons of finished iron per year. It also owned

4130-482: The type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: In a foundry, molten metal is poured into molds . Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines to pour molten metal. Traditionally, molds were poured by hand using ladles . The solidified metal component

4200-414: The type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 °C (932 °F). Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel-based alloys,

4270-535: The village of Shotley Bridge during the 17th century. During the 17th and 18th centuries, the Derwent Valley was the cradle of the British steel industry, helped by the easy availability of coal in the area and the import of high quality iron ore from Sweden via the port of Newcastle upon Tyne . However, after the invention of the Bessemer process in the 19th century, steel could be made from British iron ore (hitherto too heavily contaminated by phosphorus ) and

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4340-599: The world began to use steel, instead of malleable iron , for rails. As a result, production at Consett fell by a third. The company switched production to iron plates, demand for which was rising rapidly for shipbuilding. In 1882, Consett Iron Company began to switch production again, this time to steel plates for shipbuilding using the Siemens-Martin process . This uses open hearth furnaces to convert pig iron to steel by burning off excess carbon. The first Siemens furnaces at Consett came into production in 1883. In 1887

4410-406: The year it closed. As the rolling mills were closed in the 1970s, despite local opposition, there were discussions over the future of the plant as a whole. Consett steelworks had always avoided closure, even in difficult economic times, but in 1980 it was closed with the loss of 3,700 jobs and many more from the knock-on effects in ancillary industries. The unemployment rate in Consett became double

4480-519: Was limestone . These three ingredients were needed for blast furnaces to produce iron and steel . The town is perched on the steep eastern bank of the River Derwent and owes its origins to industrial development arising from lead mining in the area, together with the development of the steel industry in the Derwent Valley, which is said to have been initiated by immigrant German cutlers and sword-makers from Solingen , who settled in

4550-543: Was closed. A deputation of steelworkers lobbied the government in London. The social impact of the decision was often characterised by many of the local people at the time as "The Murder of a Town". After closure of the steel works the town became one of the worst unemployment black spots in Britain. In 1981, it peaked at 36 per cent – one of the worst unemployment rates of any town in the United Kingdom and around three times

4620-478: Was established in 1864 as a successor to the original Derwent Iron Company of 1840, when the first blast furnaces were introduced. Over the next 100 years, Consett became one of the world's most prominent steel-making towns, manufacturing the steel for Blackpool Tower and some of the UK's nuclear submarines . Steel dominated Consett's economy for 140 years, with the steelworks' tall cooling towers and other large plant looming over rows of terraced houses. During

4690-508: Was part of Derwentside District Council, which merged into the Durham County Council unitary authority on 1 April 2009. The Consett area is currently divided into four electoral divisions (Benfieldside; Consett North; Delves Lane and Consett South; and Leadgate and Medomsley), each electing two county councillors. The town unlike most other towns and villages in County Durham is unparished and has no town council. Consett

4760-540: Was part of the constituency of North East England in the European Parliament until 2020. Consett sits above the rural Derwent valley near the boundary of County Durham and Northumberland . The Derwent Reservoir just west of the town makes a popular leisure attraction and beauty spot. At about 900 ft (270 metres) above sea level, Consett is the third highest market town in England and one of

4830-507: Was privatised in 1955, and a new steel plate mill was opened in 1961 to supply the shipbuilding industry. About 6,000 workers were employed at the works at that time. Consett Steel Works was renationalised in 1967, this time by Harold Wilson 's government, into the British Steel Corporation , at a time when iron, coal and shipbuilding were all in steady decline in Britain. By this time British Steel had grown complacent,

4900-486: Was running below capacity and was using obsolete technology. Raw material costs for coal and oil were rising and it lacked capital for new manufacturing equipment. Government policy to keep employment artificially high increased the organisation's difficulties. Amidst intense debate and large demonstrations by workers and sympathizers, Consett Steel Works was closed in 1980. Around 3,000 to 4,000 workers lost their jobs, resulting in an unemployment rate of 35% in Consett, twice

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