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We offer full range of Casting Solutions including Sand Casting, Grey Cast Iron, Shell Mould Casting and Pressure Die Casting Learn more >
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Other Casting Processes | Investment Casting |
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Sand Casting
We offer metal sand casting services, including iron, steel and aluminum sand casting. To achieve an accurate metal sand casting, we begin with a pattern – usually a machined Ren board or an SLA prototype. Based on this pattern, we create a sand core and cavity. The sand is packed tightly with a binder to create a sand mold. After the pattern is removed, metal is then cast in the sand mold.
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Green sand provides a course finish, while air-set sand casting generates a smooth finish for your iron, steel or aluminum sand casting. Moist-bonded or resin-coated sand is packed tightly around a pattern. The pattern is removed, and the molten metal is poured into the corresponding cavity. The sand casting process is one of the most affordable methods of creating a metal casting.
Grey Cast Iron
Grey Cast iron, also known as flake graphite cast iron, is a type of type of cast iron in which most of the carbon is present as flake graphite corresponding to Form I of IS 7754. The properties of Grey Cast Iron depend on the distribution, size and amount of graphite flakes, and the matrix structure. These factors are in turn, influenced mainly by the manufacturing conditions, chemical composition, solidification time and rate of cooling in the mould. Grey cast iron exhibit low to moderate strength, low modulus of elasticity, low notch sensitivity, high thermal conductivity, moderate resistance of thermal stock, and outstanding cast ability.
Shell Mould Casting
Shell mould casting process offers better surface finish, better dimensional tolerance, and higher throughout due to reduced cycle time. A heated [200 oC - 375 oC] metal pattern is covered with a mixture of sand and thermo set plastic. This causes a skin of about 3.5 mm (0.125 in) of sand/plastic mixture to adhere to the pattern. This skin is removed from the pattern to form the "shell mold". This process can produce complex parts with good surface finish 1.25 um to 3.75 um (50 uin to 150 uin) rms, and dimensional tolerance of 0.5%. Size limit of 0.5 kg to 25 kg. Minimum thickness can be as low as 1.5mm (0.062 in) to 6.25mm (0.25 in), depending on the material. A good surface finish and good size tolerance reduce the need for machining. A fairly high capital investment is required, but high production rates can be achieved. The process overall is quite cost effective due to reduced machining and cleanup cost. The general casting tolerance is IS +/- 1/32" to 1/16" per inch. The surface roughness is 250 RMS to 500 RMS.
Pressure Die Casting
Metal – I – Cast is engaged in the manufacture of high quality aluminum and zinc die cast components in complex shapes & design to industrial houses , Locomotives , Agriculture , Defense , Medical and Racing Engine applications.
Die casting is a fast, cost-effective manufacturing process for production of high volume, net-shaped, tight tolerance metal components. It has the benefit of increased quality and repeatability, often at lower costs compared to other processes.
The die casting process is the injection under high pressure into a steel mould (or tool) of a molten metal alloy, which solidifies rapidly (from milliseconds to a few seconds) to form a net shaped component and is then automatically extracted. The die casting tool will typically produce any number of components from hundreds of thousands to millions, before requiring replacement.
We have, for our Aluminum castings, six cold chambered machines from 120 Mt to 400 Mt. For Zinc die casting we have four Hot chambered die casting machines from 50 Mt to 90 Mt. Apart form above we have 3 gravity die casting machines. |
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Aluminum Based Alloy Castings
1. All LM Series
2. AL-Sn Alloys
3. AL-Mg Alloys |
Phosphor Bronze
1. LPB1
2. PB1
3. PB2
4. PB4 |
Gun Metals
1. G1
2. G3
3. LG1
4. LG2
5. LG4 |
Bronze Alloys British Standard
1. Class I (92.5/7/0.5)
2. Class II (90/6/3/1)
3. Class III ( 78/7/0/15)
4. Class IV (83/7/0/10) 65/35 |
Leaded Bronze
1. LB1
2. LB2
3. LB4
4. LB5 |
Aluminum Bronze
1. AB1
2. AB2 |
| Copper Base Alloy Castings |
All Grades of Brass |
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