Process / Infrastructure
Die making
Using a 2D investment casting drawing that the customer submitted, we manufacture dies / tools from aluminum material. After making the necessary revisions in accordance with the requirements of the lost wax casting process, we deliver the drawing to the customer for approval. We provide technical assistance to our clients so they can create cost-effective products based on material and machining cost savings.
Wax injection
Wax is injected into dies / tools in the semi-liquid form to create a duplicate of the required castings. Wax patterns are produced using a semi and automatic hydraulic press. Every wax pattern has undergone through visual and dimensional inspection.
Wax pattern assembly
Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree.
Shelling
The wax assembly is coated with a ceramic material by repeatedly dipping it in ceramic slurries and alternately in dry beds of sand and clays. Extra coatings are added to provide the shell extra strength. Heavy or thick portions are features of any part. The most crucial stage of the shelling process is the primary coating, where a very fine grade of sand is used. This in turn results in a casting with excellent reproduction detail and the designated surface finish.
Dewaxing
The ceramic shell is heated under pressure in an autoclave and the wax is removed by melting, leaving a hollow shell.
Melting
The desired alloy is melted in an induction furnace and then poured into sintered shells, where the molten metal is then allowed to get hardened.
We have two induction melting furnace :
Furnace 1 : 350 KW & 350 Kg Crucible – 1 No.
Furnace 2 : 175 KW & 350 Kg Crucible -1 No. & 150 Kg Crucible - 1 No.
Heat treatment
We have in-house heat treatment furnace with rapid quenching facility. Furnace is calibrated as per API 6D and there is systemized control for real time temperature of different zones. We have gas fired box type furnace of 500 Kg. capacity.
Fettling
Fettling is performed using various abrasive wheels for grinding and media blasting followed by visual and dimensional inspection.
Inspection
Casting Inspection is performed using latest and calibrated instruments. Our Quality Testing Facility is well equipped with all the latest quality checking instruments.
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