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Foundry Quality Control
A foundry is a manufacturing facility that specializes in casting metal into specific shapes and sizes. Foundries typically use a variety of metals, including iron, steel, aluminum, copper, and brass, to produce castings that are used in various applications, such as automotive parts, machine components, pipes and fittings, and decorative objects.
The process of casting involves melting metal in a furnace and pouring it into a mold, which is made of sand, clay, or other materials. The metal is allowed to cool and solidify in the mold, and then the mold is broken apart to reveal the casting. The casting is then cleaned and finished to meet the required specifications.
FOUNDRY
The process of casting metal in a foundry typically involves several stages, which can vary depending on the type of casting process used. However, some common stages in the foundry process include:
Incoming inspection
STAGE 1
Incoming inspection is a quality control process that is typically conducted on incoming raw materials, components, or parts that are used in the manufacturing process. The purpose of incoming inspection is to ensure that the materials or parts meet the required specifications and are suitable for use in the manufacturing process.
If any issues or defects are identified during incoming inspection, they are documented and addressed before the materials or parts are used in the manufacturing process. This may involve rejecting the item altogether, repairing or reworking the item, or working with the supplier to resolve any issues.
Overall, incoming inspection is an essential step in ensuring that the materials or parts used in the manufacturing process meet the required specifications and are free from defects or other issues. It helps to ensure that the finished products meet the required quality standards and can help to avoid costly rework or warranty claims down the road.
Note:
All the tests are conducted in our lab. We do not buy recycled casting scrap for our castings at all as there is risk of unwanted elements getting into the final chemistry. We rely on the inspection certificates for all the alloys used in the casting bought from standard suppliers in the market.
In-Process inspection
STAGE 2
Final inspection is a critical step in the manufacturing process that is typically conducted just prior to shipping or delivering finished products to customers. The purpose of final inspection is to ensure that the products meet all required specifications and tolerances and are free from defects or other issues that could affect their performance or safety.
During final inspection, trained inspectors or technicians carefully examine each product and check for any defects or deviations from the specified requirements. This may involve using specialized testing equipment or tools, as well as visual inspection of the product’s appearance and finish.
Mold Hardness Inspection for every mold using portable mold hardness tester.
Core Scratch Hardness Inspection using scratch hardness tester.
Core Gas Determination to detect gas formation after pouring in the mold.
Sand Properties like Compressive green strength, permeability, moisture%, Loss of ignition, Volatile matter, AFS size and clay content is tested in our exclusive sand lab.
Metal Properties like metal chemistry before and after pouring with an In-House Spectro meter, Metal temperature during tapping and pouring using an Infra-Red non-contact type pyrometer. We also use Carbon silicon analyzer for cross verification of chemistry.
Final inspection
STAGE 3
Final inspection is a critical step in the manufacturing process that is typically conducted just prior to shipping or delivering finished products to customers. The purpose of final inspection is to ensure that the products meet all required specifications and tolerances and are free from defects or other issues that could affect their performance or safety.
During final inspection, trained inspectors or technicians carefully examine each product and check for any defects or deviations from the specified requirements. This may involve using specialized testing equipment or tools, as well as visual inspection of the product’s appearance and finish.
Chemical Properties of castings using the In-house Spectrometer.
Mechanical Properties of the casting like Tensile strength, Elongation and Yield strength using an In-house Tensile testing machine.
Hardness Testing of castings with a hydraulic BHN machine, Poldi tester and Electronic Dynamic hardness testing machine.
Micro Structure Analysis using a microscope and image analyzer software. We can provide all the final inspection report compiled in a standard format to the customers for every heat number poured related to the casting supply.
Casting Dimensional Inspection: Finally, the castings are dimensionally inspected randomly in regular intervals before dispatch. 100%-dimensional inspection is carried out for the new development for first sample approval procedure.
