Casting process engineering
The engineering of casting processes both for steel and iron castings is aided by CAD 3D type software (SolidEdge ST5 and Autodesk Inventor 2012). The effectiveness of these engineered processes has been verified with the most recent version of the Magmasoft software, which has been equipped with modules for the simulation of pouring, solidification and stress distribution in steel and iron castings, as well as a module for the forecasting of iron casting mechanical properties.
We are experienced in the production of carbon, low- and high-alloy steel castings, with a unit weight up to 15Mg and a carbon content of over 0.1%. For steel castings containing less than 0.07% of carbon - we are able to make castings with a unit weight up to 4Mg.
The steel is melted in electric arch furnaces of 8.5Mg capacity each, and in two-pot induction furnaces of 1Mg capacity each. In addition we have the option of metal ladle treatment by argon bubbling.
Moulds and cores are made of ester hardened alkaline phenol resin bonded sands using continuous mixer-feeders.
The heat treatment of castings is performed in three computer controlled furnaces, depending on the material grade and customer requirements. The maximum dimensions of heat treated components are 5.8 x 3.1 x 1.8 m.
We make grey iron castings weighing up to 30Mg, and S.G. iron castings with a maximum unit weight up to 25Mg.
Iron is melted in a two-pot medium-frequency induction furnace by Otto Junker, with a capacity of each crucible of 12Mg, and in a grid-frequency induction furnace with a crucible capacity of 2,5Mg.
Moulds and cores are made of furane sands that are based on reclaimed quartz sand by continuous mixer-feeders.
Non-ferrous metals castings
We are experienced in the manufacturing of castings of non-ferrous alloys such as bronze and brass, as well as in the casting of bearing metals.
We melt non-ferrous metals in two-pot induction furnaces with capacities of 1 tonne, and 50 and 100 kg. We also use an electric resistance furnace with a capacity of 200 kg.
Moulds and cores are made up of natural sands. We also offer the investment casting technology.
Machining of castings
Information from Mr. Cieślicki