MELTING CASTING AND FORGING :


CASTING :



MELTING castings made at fully-automated/ semi-automated foundries located across India. The parts are manufactured as per the specification of our customers. We meet International standards such as ASTM, AISI, BS, DIN, and JIS by monitoring every step of the manufacturing process. Our foundries have the capacity to develop parts weighing from 0.100 Kg to 1000 Kgs as a single piece



The Process Includes:

1.CENTRIFUGAL CASTING
2. Investment casting foundry
3. Sand Casting
4. Stainless Steel casting foundry
5. Aluminum casting foundry


CENTRIFUGAL CASTING:.




CASTING PROCESS


MELTlNG Centrifugal Casting is fundamentally different from nearly every other casting process currently employed worldwide. Other methods introduce and slowly solidify molten materials under static conditions, that is, one force of gravity. Using the centrifugal force in a dynamic, spinning mold cavity, metal is introduced into the mold under great force and pressure approaching 50 g’s.


Because of this pressure, dross and other contaminants are displaced to the inside of the castings and are later removed. Desirable and dense metal remains. Also, rapid solidification occurs in a predictable outside to inside direction resulting in a dense and defect free casting.


The Centrifugal Casting process is your best assurance of a high strength, defect free and refined metal component ready for use, or further machining and testing.

Weight – In excess of 25 t

Vertical Diameter – Max. 6 m

Vertical Length – Max. 2.5 m

Horizontal Diameter – Max. 1 m

Horizontal Length – Max. 4.5 m


Investment casting foundry:




The world leader in manufacturing high-quality, complex investment castings for aircraft engine, industrial gas turbine, airframe, and other applications, including the world's largest diameter investment cast components.

Weight – Max. 115 kg


Sand Casting:




Our sand molding capabilities comprise of fully automated molding machine capable of supplying medium to high volume production requirements, castings ranging in size from ounces to 50 lbs. The latest in sand molding technology gives customers the benefit of predictable and shorter lead times, low cost of inventory with consistent quality and exceptional finish of castings. Competitively priced castings are helping our customers to win in their respective markets.


Manufacturing Processes:

• CO2 Sand Moulding (2kgs to 100 Kgs)
• Shell Moulding (100 gms to 10 kgs)
• Weight – Min. ≤ 1 kg – Max. 125 t


Stainless Steel casting foundry:


Steel castings are used in the agricultural, construction, manufacturing, power generation, processing, and transportation industries. Like all foundries, steel casting foundry is a flow line production system in which the sequence of operations is fixed and the workflow is in a single direction. The main manufacturing process of steel casting foundry includes pre-casting stage, casting stage, and post casting stage. The heat treatment process is a crucial factor in steel casting. Steel casting foundry differs from iron foundries in the nature of the sand used in all the molds being dried very hard and in the flasks or molding boxes having fewer bars than those used in iron foundries. In the steel casting foundry most steel castings are made in the open – hearth furnaces, by which it is possible to obtain a more controllable product, and in larger quantities. Steel can be melted in a crucible in an ordinary brass furnace by increasing the height of the chimney to get a sharper draught. All steel has to be poured at a much higher temperature than iron. It, therefore, contracts more, the hotter it is poured the more it shrinks. The shrinkage in steel castings is far from uniform, and it is, therefore, necessary to allow a larger margin on machining on important surfaces and in cored holes than in the case of iron.


Aluminum casting foundry:




Aluminum casting foundry caters majorly to the Automobile Industry. Aluminum has lightweight and it attracts the automobile sector seeking to reduce vehicle weight to improve fuel efficiency and reduce emissions. One of the major challenges facing the Aluminum casting foundry is obtaining of aluminum scrap. Aluminum casting foundry has been more and more catering to the needs of downstream industries. The two major types of aluminum alloys include wrought alloys and casting alloys. Wrought aluminum is used for extruded shapes such as aluminum cans, tubing to name a few. Their properties are tailored for die forging, and not for casting work. Aluminum is cast in more alloys with a wider range of physical and mechanical properties by more processes. As said earlier the most important trend affecting aluminum casting production is its continuous growth in automotive applications. The advantages of aluminum for many powertrain components , including transmission cases, oil pans, cylinder heads and engine blocks have been reflected in its wide adoption. Cast aluminum has replaced cast iron in many engine blocks.