Sand Casting

Foundry Infrastructure
  • High Pressure Disamatic moulding line with an average production rate about 150 moulds/hour.
  • Conventional Machine Moulding Line with box size up to 700x600x200/250
  • Automatic sand plant of capacity 20T/hour
  • Well-equipped pattern shop for maintenance/alteration of patterns.
  • Dual track medium frequency induction furnace of capacity 3 tonnes per crucible
  • Core Shop with no bake core shooter and Co2 core making facilities.
  • Three shot blasting machines (500kg, 300kg, & Tumb blast machine)
  • Machine shop with CNC Turning centre, centre lathe, drilling machines and surface grinding machine.
  • Well equipped laboratory to carry out mechanical, metallurgical properties of various castings which includes Spectrometer, Metallurgical Microscope and Magnetic particle testing facilities, UTM, Hardness tester, sand analyzer, Tensometer, etc.
  • The company presently employs about 126 employees out of whom 58 are staff and executives.
  • Company is located at Myleripalayam on the Pollachi Main Road at a distance of 20km from Coimbatore in Tamil Nadu.
AREA DETAILS
Total Area of the Plant - 430000 Sq Ft.
Buildings - 50000 Sq Ft.
Open Space - 38000 Sq Ft.
QUALITY SYSTEMS
SO/TS 16949 - Certified by BVQI on 26th April 2005. Date of expiration: 17 March 2008.

Salient Features – For Production of SG Iron Castings

    I . Melting
  • Two medium frequency Induction Furnace Crusibles with dual track (Inductotherm) 1500kw power electrical.
II . MG Treatment
Tundish covered ladle is used for treating metal with Fe Si Mg.
Treatment Alloy : 5 to 7% Fe.Si.Mg .
Batch Weight : 140-170Kgs for (DISAMATIC)
Ensured through DIGITAL (200 kgs for ARPA ) Weighing scale hooked to the ladle
Alloy addition : 1.3-1.50%

III . Inoculation
Mg treated metal is inoculated with Fe.Si inoculant when it is transferred from treatment ladle to pouring ladle.
Inoculant : Barium base inoculant Barionoc (Elkem)/Bacal(Snam)
Additions : 0.5 to 0.6%

IV. Moulding Machines

a. DISAMATIC 2110
High Pressure vertically parted Flaskeless green sand mould.
Mould Size : 500x400
Production rate : 120 to 180 moulds per/hr
Maximum casting weight: : 8.5kgs

b. ARPA 450
Conventional jolt squeeze molding line
Box Size : 700x600x200/250
Production rate : 40 moulds per/hr
Maximum casting weight : 60 Kgs

V Sand Plant
20 Tons/hour automated sand plant with batch weighing system recycles the system sand.
Return sand : 300-400 kgs
New sand : 25-35 kgs
Bentonite : 3.75-5 kgs
Coal Dust : 0.5 - 1 kg

VI Pouring
A simple manual pouring system with the tea spout ladle ensures smooth flow of metal in the mould.
Pouring Time = 5 Seconds to 11 Seconds

VII Casting Solidification
Casting are getting solidified when the moulds are carried through Automotic Mould Conveyor (12meters in length) and Synchronised Belt Conveyor (24meters in length). It takes 45 to 60 minutes for the moulds to fall on the vibrator.

VIII Casting Separation
Castings are separated manually from the moulds as the moulds are falling on shakeout vibrator. The separated mould sand is automatically taken for recycling through the return sand conveyors.

IX Runner/Riser breaking
Runners and risers are knocked off from the castings manually by using wedge.

X Fettling and shot blasting
Castings are shot blasted twice, once before fettling and second time after fettling.

XI Packing and Preservation
Castings are 100% inspected for visual surface defects immediately after final shot blasting. Then they are given preservation coating (if required) and packed as per customer requirements.


PROCESS AND QUALITY CONTROL FOR SG IRON PRODUCTION

I Charge mix control
40-50 % Low Manganese steel/Pig Iron
50-60 % returns

II Charge Material Composition Control Steel Scrap
Silicon : 1.8% max
Manganese : 0.40%max
Sulphur : 0.04%max
Chromium : 0.05%max

III Base Metal composition control
SG 400/12 SG 500/7 SG700/2
Total Carbon 3.60-3.75% 3.50-3.65% 3.5-3.60%
Silicon 1.5-1.6% 1.4-1.6% 1.1-1.30%
Manganese 0.35%max 0.35%max 0.35-0.45%
Sulphur 0.020%max 0.020%max 0.020%max
Phosphorous 0.04%max 0.04%max 0.04%max
Copper 0.15%max 0.30-0.45% 0.85-1.0%.


IV Final metal composition (in the casting)
SG 400/12 SG 500/7 SG 700/2
Total Carbon 3.50-3.70% 3.50-3.60% 3.45-3.60%
Silicon 2.5-2.80% 2.40-2.70% 2.2-2.40%
Manganese 0.35%max 0.35%max 0.35-0.45%
Sulphur 0.015%max 0.015%max 0.015%max
Phosphorous 0.04%max 0.04%max 0.04%max
Copper          0.15%max 0.30-0.45% 0.85-1.0%

V Temperature Control
Tapping Temperature : 1550 Deg C max.
Pouring Temperature : 1300 Deg C min as measured in the sprue cup of the mould immediately after pouring

VI Magnesium Fading Control
Treatment quantity : Weighed using dital electronic balance hooked to the treatment ladle
Mg Alloy addition : 1.30 to 1.50% weighed for ever batch
Covering Steel : Steel Punchings equivalent to alloy wt
Timer : Hooter is provided in pouring area to give alarm when set timer is Competed
Modularity : Every treatment in the AFS Coupon from last poured metal
Chill Test : Every treatment in wedge sample from last poured metal

VII Inoculation
Inoculation : 0.45-55% (Barinoc from Elkem or Bacal from Snam)

VIII Moulding Sand Mix Control
Compatibility : 35 to 45%
Permeability : 90-140
Green Compression
Strength : 1600-2000 grams/sq.cm min
Active Clay : 7 to 11%

IX Mould Hardness
Mould Hardness : 80min

X Inspection and Testing
Final Composition : From the last poured sample of each treatment
Microstructure : One per date code
Hardness : 4 nos per part number per day
Tensile/Elongation : One number per part number per day
Visual Inspection : 100% before moving to warehouse
Dimension : One per cavity per day
Internal Soundness : As agreed with the customer
List of Testing Equipments