Facilities

Foundry – Castings

We supply Ferrous and Non-ferrous castings made at fully-automated/ semi-automated foundries located across Asia. 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 pieceThe Process Includes:

Process Moulding Line Material Grade Capability
Green Sand
  • DISA
  • HUNTER
  • ARPA
  • IMF
  • Gray iron
  • Ductile Iron
  • Malleable Iron
  • Ni-resist Iron
  • Alloy Steel
  • Mould size (max) : 1m x 1m
  • Weight Range : 1 Kg ~ 30 Kgs
  • Dimensional Tolerance +/- 2.5mm
  • Surface finish up to Ra 12.5
Furan Resin / No Bake
  • DISA
  • HUNTER
  • IMF
  • Gray iron
  • Ductile Iron
  • Malleable Iron
  • Ni-resist Iron
  • Alloy Steel
  • Carbon Steel
  • Mould size (max) : 1.5m x 1.5m
  • Weight Range : 30 Kg ~ 150 Kgs
  • Dimensional Tolerance +/- 2 mm
  • Surface finish up to Ra 6.3
Co2 / Floor Mould
  • IMF
  • SPM’s
  • Gray iron
  • Ductile Iron
  • Malleable Iron
  • Ni-resist Iron
  • Alloy Steel
  • Carbon Steel
  • Mould size (max) : 3m x 3m
  • Weight Range : 100 Kg ~ 1000 Kgs
  • Dimensional Tolerance +/- 2.5mm
  • Surface finish up to Ra 6.3
Shell / Resin
  • SPM’s
  • Gray iron
  • Ductile Iron
  • Malleable Iron
  • Ni-resist Iron
  • Alloy Steel
  • Carbon Steel
  • Mould size (max) : 500mm x 500 mm
  • Weight Range : 0.250 Kg ~ 20 Kgs
  • Dimensional Tolerance +/- 0.75mm
  • Surface finish up to Ra 3.2
Investment Wax
  • SPM’s
  • Ductile Iron
  • Alloy Steel
  • Stainless Steel
  • Carbon Steel
  • Aluminum
  • Mould size (max) : 500mm x 500mm
  • Weight Range : 0.100 Kg ~ 20 Kgs
  • Dimensional Tolerance +/- 0.06 mm
  • Surface finish up to Ra 1.6
Gravity Die
  • SPM’s
  • Aluminum
  • Bronze
  • Brass
  • Mould size (max) : 1m x 1m
  • Weight Range : 0.5 Kg ~ 50 Kgs
  • Dimensional Tolerance +/- 0.4 mm
  • Surface finish up to Ra 3.2

Iron Casting Foundry India

Iron Casting foundry

Iron Casting Foundry China

Investment casting foundry

Aluminum casting foundry

Steel casting foundry

    

About Iron Casting Foundry

Iron Casting Foundry India

A foundry is a factory that produces metal castings. Iron casting foundry India has been the most sought after by companies in USA and Europe. Metal casting has been an art long before it was a science. In terms of number of operating units India ranks 2nd after China as far as number of operating foundries are concerned. Iron casting foundry India are classified as Steel/Alloy/ Stainless Steel foundries, Grey Iron Foundries, Ductile Iron (SG Iron) Foundries, Non Ferrous Foundries, Artware Foundries. Calmet supplies ferrous and non – ferrous castings made at fully- automated / semi –automated foundries located across Asia. Iron casting foundry India follow three stages of casting process. This include pre-casting, casting, post-casting. Iron casting foundry India takes more care in the selection and production of suitable pattern equipment. Calmet ensures that each casting is processed through our QC staff with inspection records for every shipment. The casting process involving the use of sand as molding medium can be classified as sand molding process. These are used for over seventy percent of castings produced. The stages involved in the sand molding process include sand preparation, pattern making, core making, molding and closing. Iron casting foundry India use different kinds of sand depending on the application and the nature of molding process.

Iron casting foundry China

China is now the world’s largest producer of foundry products. China’s rapidly expanding iron casting foundry industry reflects burgeoning demand from the country’s fast growing manufacturing sector and foreign direct investment. The largest end user of gray iron castings is the motor vehicle industry. Guangdong is especially rich in iron ore and foundries has been established throughout the province. Light iron construction castings are used highly in valve, service and meter boxes employed in utility systems. The growth of the Chinese iron casting foundry industry is directly related to increased demand from china’s construction sector and manufacturing industries especially motor vehicles production. Calmet having its office in Shanghai, China has taken care on these factors while determining the price for its supply of iron casting from china.

Investment casting foundry

Investment Casting is a process of using a sacrificial pattern, which is coated with a ceramic shell. The model is then removed by using an autoclave or furnace. Metal is then poured into the remaining cavity. The design for investment casting include wax, or plastic temperature, heat treatment temperature all bear directly on tolerances required in the investment casting process. The amount of tolerance required to cover each process step is dependent, basically, on the size and shape of the casting and will vary from foundry to foundry. One factor which however remains constant. The cost of any casting increases in proportion to the preciseness of specifications, whether on chemistry, non destructive testing or tolerance brands. Investment casting has been clearly identified as the process to use to form the initial billet. The sequence of operations for the investment casting is determined on the basis of the layout of the investment casting line. The method of flasking is used where the wax pattern / sprue assembly is placed in an investment flask and this is then filled with ceramic slurry, which is further left to dry and solidify. In terms of tooling, the investment casting will not be considered further as the tooling in this instance will be unique to the component.

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 work flow is in a single direction. The main manufacturing process of steel casting foundry include pre-casting stage, casting stage, and post casting stage. The heat treatment process is a crucial factor in steel casting. Steel casting foundry differ from iron foundries in the nature of the sand used in all the moulds being dried very hard and in the flasks or moulding 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 light weight 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 down stream 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 power train 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. On the world ranking of consumption of Aluminum casting industry are United States and West Germany. Indian manufacturers produce comparable merchandise and are significant producers of aluminum.