Assembly Components
Assembly Components
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SGI Castings
SGI Castings
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Shell Mould Casting
Shell Mould Casting
Shell Mould Castings Manufacturers
Shell mold casting, also known as shell molding or shell core casting, is a precision casting process that uses a reusable mold or shell made of a thermosetting resin-coated sand. The shell mold is produced by forming a thin layer of sand mixture around a pattern, which is heated to cure the resin and create a hard shell. This shell is then removed from the pattern and assembled with other shells to create a complete mold.
Applications
- Shell moulding is suitable for mass production of thin - walled casting in any metal having the size of few grams to 20 kg most commonly used Concrete machinery, Pipes & Elbows, Shot blasting machine spares.
- Total capacity of 150 tons / Month of shell mould production.
- Casting manufactured steel, Ductile iron, Ni-Resist & Abrasion resistant casting.
The shell mold casting process typically involves the following steps:
- Pattern creation: A pattern, usually made of metal or plastic, is created to match the desired shape of the final casting.
- Shell mold formation: The pattern is heated and coated with a mixture of resin and sand to create a sand shell around the pattern. This shell is sufficiently thin to allow for even and efficient heat transfer during casting.
- Shell assembly: Multiple shell halves are assembled together to create a complete mold. Cores or additional features may also be added to the mold at this stage.
- Mold preheating: The assembled mold is preheated to remove any moisture and ensure the shell is fully cured and ready for casting.
- Cooling and solidification: After pouring, the mold is allowed to cool, and the metal solidifies inside the mold cavity.
- Mold removal: Once the casting has cooled and solidified, the shell mold is broken or removed to reveal the finished casting.
Shell mold casting offers several advantages, including high accuracy and dimensional consistency, improved surface finish, and the ability to cast complex shapes with thin walls. It is commonly used in the production of small to medium-sized metal components, such as engine parts, pump housings, and industrial equipment components.
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Machined Casting
Machined Casting
Machined Casting Manufacturers
- STEEL & ALLOY STEEL CASTING
- NI HARD CASTINGS
- NI RESIST CASTING
- Spheroidal graphite Iron casting (Ductile Iron )
- C.I CASTINGS (Grey Iron )
Fully Machined Cast Components
- Valves & pumps components.
- Ni-Resist D2 Components for gate and globe valves-sleeves,stem nunts & Bushes.
- Ni- Resist liners.
- Ni-Resist machined casting for Mechanical Seals.
- Valves bodies, in gray Iron & S.G Iron (Ductile Iron) and alloy steel grades.
- Flanges, Bonnets,Hand wheels in Steel & alloy Steel.
- Pump impellers in Ni-hard.
- General Engineering machined components in various types of casting and steels.
Machined Castings Manufacturers
Machined castings refer to cast metal parts that have undergone additional machining operations after being cast. These additional machining processes can include milling, drilling, turning, grinding, and any other necessary operations to achieve the desired dimensions, tolerances, and surface finish.
The process of machining castings involves the following steps:
- Casting production: The castings are produced using various casting methods such as sand casting, investment casting, or die casting. These processes involve pouring molten metal into a mold and allowing it to solidify and take the shape of the mold.
- Casting cleaning: After the castings have cooled and solidified, they are removed from the mold and undergo cleaning processes to remove any residual sand, gating systems, or other casting debris.
- Machining setup: Once cleaned, the castings are set up on a machining tool, such as a lathe, milling machine, or CNC machine. Fixtures or clamps may be used to hold the casting securely in place during machining.
- Machining operations: The casting then undergoes various machining operations to shape it to the required dimensions. This can include removing excess material, creating features such as holes or threads, and achieving the desired surface finish.
- Quality control: During and after machining, the castings undergo quality control inspections to ensure they meet the specified dimensions and tolerances. This can involve the use of measuring instruments such as calipers, micrometers, or coordinate measuring machines.
- Finishing operations: Once the machining operations are complete, additional finishing processes such as deburring, polishing, or coating may be applied to enhance the appearance and functionality of the machined castings.
Machined castings are commonly used in industries such as automotive, aerospace, machinery, and construction. They offer the advantage of combining the versatility and intricate shapes achievable through casting processes with the precision and accuracy achievable through machining operations. This allows for the production of complex parts with tight tolerances and high-quality surface finishes.
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Machined Alloy Steel Casting
Machined Alloy Steel Casting
Machined Alloy Steel Casting Manufacturers
- Steel Castings as per ASTM 216 Grade-WCB, Etc.
- SS 410, SS 316, SS 304 castings.
- Stainless steel castings such as CF8, CF8M, Cn7M, HK 40, Alloy 20.
- ASTM A-217grades like WC1, CA-15, CA 40 etc.
- Various alloy steel castings as per ASTM and AISI standards.
Chemical Composition
| STEEL GRADE | Carbon | Manganese | Silicon | Sulfur | Phosphorus | Tensile Strength | Yield Point | Elongation in 2 in. | Reduction of Area |
| Max % / Range | Min.ksi(Mpa)/Range | Min.ksi(Mpa)/Range | Min% | Min% | |||||
| ASTM A27, Grade N-1 | 0.25 | 0.75 | 0.80 | 0.06 | 0.05 | N/A | N/A | N/A | N/A |
| ASTM A27, Grade N-2 | 0.35 | 0.60 | 0.80 | 0.06 | 0.05 | N/A | N/A | N/A | N/A |
| ASTM A27, Grade U60-30 | 0.25 | 0.75 | 0.80 | 0.06 | 0.05 | 60(415) | 30(205) | 22 | 30 |
| ASTM A27, Grade 60-30 | 0.30 | 0.60 | 0.80 | 0.06 | 0.05 | 60(415) | 30(205) | 24 | 35 |
| ASTM A27, Grade 65-35 | 0.30 | 0.70 | 0.80 | 0.06 | 0.05 | 65(450) | 35(240) | 24 | 35 |
| ASTM A27, Grade 70-36 | 0.35 | 0.70 | 0.80 | 0.06 | 0.05 | 70(485) | 36(250) | 22 | 30 |
| ASTM A27, Grade 70-40 | 0.25 | 1.20 | 0.80 | 0.06 | 0.05 | 70(485) | 40(275) | 22 | 30 |
| ASTM A148,Grade 80-40 | N/A | N/A | N/A | 0.06 | 0.05 | 80(550) | 40(275) | 18 | 30 |
| ASTM A148,Grade 80-50 | N/A | N/A | N/A | 0.06 | 0.05 | 80(550) | 50(345) | 22 | 35 |
| ASTM A148,Grade 90-60 | N/A | N/A | N/A | 0.06 | 0.05 | 90(620) | 60(415) | 20 | 40 |
| ASTM A216,Grade WCA | 0.25 | 0.70 | 0.60 | 0.045 | 0.04 | 60-85(415-585) | 30(205) | 24 | 35 |
| ASTM A216,Grade WCB | 0.30 | 1.00 | 0.60 | 0.045 | 0.04 | 70-95(485-655) | 36(250) | 22 | 35 |
| ASTM A216,Grade WCC | 0.25 | 1.20 | 0.60 | 0.045 | 0.04 | 70-95(485-655) | 40(275) | 22 | 35 |
Applications
- Transport : Automobile, aerospace, railways and shipping.
- Heavy Equipment : Construction, farming and mining.
- Machine Tools : Machining, casting, plastics molding, forging, extrusion and forming.
- Plant Machinery : Chemical, petroleum, paper, sugar, textile, steel and thermal plants.
Machined Alloy Steel Castings Manufacturers
- Machined alloy castings refer to cast metal parts that have been machined to precise specifications and tolerances. These castings are typically made from alloys such as aluminum, magnesium, or zinc, which are known for their excellent strength-to-weight ratio, resistance to corrosion, and ease of machining.
- The casting process for machined alloy castings involves melting the alloy material and pouring it into a mold. The mold is typically made from a sand or ceramic material and is designed to produce a specific shape and size of the casting. Once the casting has solidified, it is removed from the mold and undergoes a series of machining operations to achieve its final shape and dimensions.
- Machining may involve processes such as cutting, drilling, or grinding, and may be done manually or with computer-controlled machines. Machining allows for fine-tuning of the casting's dimensions and surface finish, ensuring that the final product meets the customer's requirements for accuracy and quality.
- Machined alloy castings are used in a wide range of applications, including aerospace, automotive, medical equipment, and consumer products. They are often used in critical components that require high strength and precise tolerances, such as engine parts, hydraulic systems, and structural components.
- In summary, machined alloy castings are cast metal parts that have been machined to precise specifications and tolerances. They are made from alloys such as aluminum, magnesium, or zinc, and are used in a variety of industries and applications where high strength, resistance to corrosion, and precise dimensions are required.
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ASTM-A-532 Casting
ASTM-A-532 Casting
Astm A532 Casting Manufacturers
- These alloys are usually called high chrome white irons.
- ASTM A532, DIN EN 12513 and BS4844-1996 and IS:4771-1985.
- The ASTM A532 specification refers to a group of high chrome white cast irons that have been engineered to offer high abrasion resistance to gouging.
- Abrasion Resistant casting.
Chemical Composition
Chemical composition, max(unless range is given)%
| Specification | Grade or class | C | Si | Mn | S | P | Ni | Cr | Mo | Cu | Hardness max, HB | |
| ASTM A5332 | Abrasion Resistant Iron | I-A | 2.80-3.60 | 0.80 | 2.00 | 0.150 | 0.300 | 3.3-5.0 | 1.4-4.0 | 1.0 | 550min | |
| I-B | 2.40-3.00 | 0.80 | 2.00 | 0.150 | 0.300 | 3.3-5.0 | 1.4-4.0 | 1.0 | 550min | |||
| I-C | 2.50-3.70 | 0.80 | 2.00 | 0.150 | 0.300 | 4.0 | 1.0-2.5 | 1.0 | 550min | |||
| I-D | 2.50-3.60 | 2.00 | 2.00 | 0.150 | 0.100 | 4.5-7.0 | 7.0-11.0 | 1.5 | 500min | |||
| II-A | 2.00-3.30 | 1.50 | 2.00 | 0.060 | 0.100 | 2.5 | 11.0-14.0 | 3.0 | 1.2 | 550min | ||
| II-B | 2.00-3.30 | 1.50 | 2.00 | 0.060 | 0.100 | 2.5 | 14.0-18.0 | 3.0 | 1.2 | 450min | ||
| II-D | 2.00-3.30 | 1.50 | 2.00 | 0.060 | 0.100 | 2.5 | 18.0-23.0 | 3.0 | 1.2 | 450min | ||
| III-A | 2.00-3.30 | 1.50 | 2.00 | 0.060 | 0.100 | 2.5 | 23.0-30.0 | 3.0 | 1.2 | 450min |
Applications
- Mining and mineral processing :Ni Hard white iron is used in crushers, grinding mills,and wear liners to withstand the abrasive nature of rocks and minerals.
- Cement and concrete production:It is employed in cement plants for crushing and grinding application,where the material needs to endure heavy wear and impact.Also used for concrete handling piping system.
- Power generation:Ni -Hard white iron is utilized in coal handling system,pulverizes,and ash pipelines due to its excellent wear resistance in high temperature environment.
- Dredging and pumping: The wear resistance and toughness of Ni -Hard white iron make it suitable for dredge pumps,impellers&other components that handle abrasive slurries.
- Steel manufacturing: Ni Hard white iron is used in various stages of steel production,including blast furnace bells,hot metal transfer equipment and continuous casting components.
ASTM A-532 Castings Manufacturers
- ASTM A532 is a standard specification for abrasion-resistant cast iron alloys used in a variety of applications that involve high wear and impact resistance. These castings are suitable for use in mining, construction, cement, and other industries where the casting is exposed to high abrasion, impact, or heat.
- The ASTM A532 specification covers several different grades of abrasion-resistant cast iron, which vary in their chemical composition, microstructure, and hardness. Some of the most common grades of ASTM A532 castings include:
- Ni-Hard: This grade of cast iron contains nickel and chromium, which provide excellent wear resistance and toughness. Ni-Hard castings are used in applications such as grinding mills, crushers, and cement mixers.
- Hi-Chrome: This grade of cast iron contains high levels of chromium and other alloying elements, which provide exceptional wear resistance and hardness. Hi-Chrome castings are commonly used in mining equipment and machinery, where the casting is exposed to high abrasion and impact.
- White Iron: This grade of cast iron is known for its high hardness and abrasion resistance. It is commonly used in applications such as pump and valve components, where the casting is exposed to abrasive wear.
- ASTM A532 castings are made using a variety of casting methods, including sand casting, investment casting, and centrifugal casting. The casting process can be customized to produce castings of various shapes, sizes, and complexities that meet the customer's specific requirements.
- In summary, ASTM A532 castings are abrasion-resistant cast iron alloys used in various applications where the casting is exposed to high abrasion, impact, or heat. They are available in several different grades, each with its own unique properties, and can be made using a variety of casting methods to produce high-quality, custom parts.
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Ni-Resist Casting
Ni-Resist Casting
Ni Resist Casting Manufacturers
- Ni resist casting as per ASTM A436, ASTM A439, DIN 1694 and DIN EN 13835.
- Ni resist casting as per any country’s national standard can be manufactured by us.
- Ni-Resist or Ni Resist alloy grades are austenitic gray cast iron casting grades that provide good hardness, dampening, and some corrosion resistance.
- We ensure strict checking of the microstructure,chemical composition and mechanical properties of castings of each heat to match with international standards.
- We can perform precision machining on any component as per your requirements.
Astm A 439 Grade Chemical Composition
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Astm A 439 Grade Chemical Composition
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Applications
Pump & Valve, piston Ring Insert, Bearings, Cylinder Liners, Chemical Industries, Oil Industries, Marine, Food handling & processing, petroleum industries.
Ni Resist Casting Manufacturers
- Ni-Resist is a family of austenitic cast iron alloys that are known for their excellent resistance to corrosion and high-temperature oxidation. Ni-Resist castings are used in various industries where the castings are exposed to acidic or corrosive environments, such as chemical processing, marine, and power generation.
- Ni-Resist castings are composed of alloying elements such as nickel, chromium, and silicon, which provide excellent corrosion resistance and high-temperature strength. The nickel content in Ni-Resist castings ranges from 14% to 36%, providing increased resistance to high-temperature oxidation.
- The casting process for Ni-Resist involves melting the metal in a furnace, pouring it into a mold, and allowing it to solidify. Ni-Resist is a highly fluid metal, meaning that it can be poured into intricate molds without the risk of shrinkage or cracking.
- Once the casting has solidified, it is machined into its final shape. Ni-Resist castings are known for their excellent machinability, which allows for precision finishing and tight tolerances.
- Ni-Resist castings have many applications, including pump and valve components, chemical reactors, and exhaust manifolds. They are also used in marine applications, where the metal's resistance to seawater corrosion is necessary.
- Overall, Ni-Resist castings offer excellent resistance to corrosion and high-temperature oxidation, making them an essential material for many industries.