Process/Technology
The continual improvement of process and technology is designed on regular interval to meet the standard and customer requirements
Casting model is made with machining allowance, contraction allowance, metal padding and draft.
The required components are run with the simulation software to predict the internal soundness.
The simulation helps to identify the defects and to eliminate them with further iterations by using right gating & risering system
The right gating system is followed to have laminar flow and the optimum risering to meet the feed volume requirements
The patterns are manufactured either in wood (or) Aluminium based on usage and the surface finish requirements.
The patterns are provided with required machining allowance.
Deffree has dedicated storage area having more than 4700 patterns.
The process employed is co2 sand moulding which generates the lowest amount of gases due to mould-metal reaction.
The moulds are used with excellent zircon wash to prevent metal penetration.
The exothermic / insulating sleeve materials are used for the effective feeding of risers.
The chills are used for directional solidification and to promote effective feeding distance.
Deffree has different sizes of induction furnaces to handle different alloys and weight requirements.
The furnaces are equipped to handle any kind of Deoxidation and degassing procedures for achieving clean metal.
Induction Furnace :
- Inductotherm-dual track
- Pillar Induction
| Furnace Size | |
|---|---|
| 3000 kgs | 1 no |
| 2000 kgs | 1 no |
| 1500 kgs | 1 no |
| 1000 kgs | 2 nos |
| 300 kgs | 1 no |
| 200 kgs | 2 nos |
| 100 kgs | 1 no |
Tea-spout Ladles of 100 kg, 250 kg, 500 kg, 1000 kg & 4000 kg are used depending on the metal volume requirements.
Ladles are insulated with high refractory materials to withstand high temperature and to overcome heat losses.
The pouring design parameters are ensured while filling the molds.
The castings with sprue, runner, ingate and risers are removed and further shot blasted and ground to meet the drawing finish requirements.
An Electrical resistance calibrated furnaces of 7.0 MT and 0.3 MT with Quenching tanks are used to handle temperatures upto 1220°C.
The furnace is equipped to generate time-temperature charts.
The following treatments are carried out
- Solutionizing
- Precipitation / Age Hardening
- Annealing
- Any customised cycles
For all nickel-base alloys, Aluminium Bronze & Nickel Silver castings, Dye-penetrant examination and Radiography testing are performed.
MPI and UT are not applicable for these grades.
The operators are qualified to ASNT level 2.
The chemical and Mechanical properties are analysed for every melt cycle to ensure that the customer & standard requirements are met.
- Spectrometer (32 elements ARL)
- 40 Mt UTM machine
- Hardness testing machine
- Sand Testing Laboratory (Permeability, Core gas, Sand moisture teller, Mold Hardness, Mold moisture tester)
The machine shop is equipped with VTL machines and Radial Drilling Machine to perform machining of valve bodies, bonnets and internals. It has the capacity to machine upto 4 metric ton single piece casting weight.
- HWACHEON VT 650 CNC
- STANCO 1100 (Table dia) CNC
- Radial drilling – 50Ø
- Conventional Lathes.
The machined castings are tested for hydro leaks upto 2500 pressure class rating having 1100 X 1400 day light.
