Wieland Lone Star Casting & Machine in Kilgore, TX, is a precisely controlled, vertically integrated, carefully orchestrated production of essential aviation components. Its parts are specific to landing gears, serving new builds as well as the maintenance, repair and overhaul market.
The aerospace operation was acquired by Germany-based Wieland last year, expanding its workforce, equipment inventory, output and role as a key supplier of centrifugally-cast aluminum bronze bushings for clients around the globe.
"What started with a handful of people grew to a full production shop that offers everything in-house, including heat treat and mechanical testing. There are only a handful of suppliers in the world that do what we do," said Operations Manager Ryan Rector.
Lone Star starts with raw materials or in-house recycled material to make aluminum nickel bronze alloys to the required specification. It is a carefully monitored proprietary recipe that is quality-tested before the alloy is poured into ingots, roughly 20 lbs. each with a golden sheen. The casting department will then re-melt the ingot for casting production, each one put through Lone Star's heat treat and quench procedure when the specification requires. The company's machinists constantly monitor the consistency and quality of the material. Cylindrical castings are machined to tailored sizes according to client drawings.
With its vertical integration and precision focus, Lone Star is a minimum-waste operation. In addition to buying shavings back from the customer, the company targets maximum efficiency in its alloy purification, capturing the slag byproduct of the melting process.
"As we 'clean' our material during the melt, a dross of impurities is skimmed from the top and separated," noted Rector. "We then sell this to smelters who can recover the copper."
Lone Star was introduced to Wieland in 2022 through one of its customers, Busby Metals, a previous acquisition.
"Lone Star and Busby have a good and long history together. Now we are a part of the same family," Rector said. "The operation's workforce has all but doubled since the acquisition-there are currently 22 employees on the roster with more hires planned in the immediate future as a second foundry shift takes shape."
For more information contact:
Wieland Lone Star Casting & Machine
3102 Maverick Drive
Kilgore, TX 75662
903-986-8300