Sujan Industries is one of the few renowned Class A certified Stainless steel casting manufacturers in India that produces and supplies the highest quality Steel, and Ductile Iron Casting products. With the latest equipment available in the industry, we have built a team of skilled professionals with extensive experience in the Sand Casting. Sand casting is also known as sand moulded casting is a metal casting process characterized by using sand as a mold material. Moulds made of sand are relatively cheap & sufficiently refractory even for steel foundry use. Over 70% of all metal casting is produced via a sand casting process.
As the apex Steel Casting Foundry in Mumbai, India, Sujan Industries has gained wide expertise in manufacturing casting products for Rail application, pump, valve, and general engineering applications, etc. to meet Global stringent requirements in various MOC like Plain carbon steel, Alloy steel, high nickel alloys, Stainless Steel, Duplex Steel, Super Duplex Steel, Ductile Iron and ADI in the weight range of 5 kg to 1000 kg single piece.
Situated around 50,000 sq.ft. area, the manufacturing plant at Sujan Industries is equipped with state-of-the-art instruments and has the capacity of producing 300 MT good casting products per month.
Alloy Steel is alloyed with a variety of elements in total amounts between 1.0% and 50% by weight to improve its mechanical properties. Stainless steel is iron-based alloys that contain a minimum of approximately 11% chromium, a composition that prevents the iron from rusting. Cast steel is a solid metal object which is made of iron with a maximum carbon content of almost 0.75% and by filling the void within a mold with liquid steel. Ductile iron is a type of iron that can be characterized by its excellent strength, ductility, and wear resistance. The shape of this metal is ball-shape, hence it can resist impact, swelling, and everyday wear and tear. Austempered Ductile Iron (ADI) casting is the latest addition to the group of ductile iron. At Sujan Industry, we produce it by giving the conventional ductile iron a unique austempering heat treatment.
At Sujan Industries, we execute the entire manufacturing process with optimal accuracy, performance, and quality. The process includes the following steps:
1. Project and Design
The process for the making of casting is started when we receive the order from our client. So at the initial stage, we study the feeding and filling system of the pieces that we have to build and craft the required patterns and core boxes. Then our R&D team does the research and creates computer simulations of steel casting solidification.
This way we make sure that the end products are of the highest quality. Then, the construction of the patterns and core boxes, the tools that we use for making sand moulds and sand cores, where we pour the liquid steel until the solidification is done, is delivered to the qualified modelers.
2. Moulding and Core Making Section
At Sujan Industries, the top Stainless Steel Casting Manufacturers in India the moulding shop is equipped with the state-of-the-art moulding machines where we have continuous sand mixers for moulding and core making. We have a mechanical reclamation plant and 3 numbers of EOT cranes are also there in the plant.
The core making section is an auxiliary moulding section which is the part of the process where sand cores are made using the core boxes. Based on the application, the core making is done with No Baking Sand System and CO2 Sand System.
The sand is processed in the continuous mixer and dumped on casting patterns to make it compact and compressed and shaping the required pieces of the sand mould. Once we compact the sand mould, we separate the casting pattern and reuse it for making new sand moulds.
The cores produced in the core making section, are placed inside the sand moulds to determine the inner shape of the workpiece. Then, the sand moulds are united and closed and finally are moved to the storage area where the melted steel is poured into the moulds.
3. Melting and Casting
The Furnace at Sujan Industries is equipped with the pots that can contain 1000 Kgs and 500 Kgs capacity of liquid metal. We execute the leap pouring & tea spout method and for accuracy, the temperature control furnace is equipped with a duly calibrated pyrometer.
So, to obtain the fluid steel, the scraps and ferroalloys are melted in an electric furnace. The frequency is kept medium in the melting section. Depending upon the kind of steel alloys to be produced, like, corrosion-resistant steels, stainless steels, heat resistant steels, carbon steel, high nickel alloy steel, etc., we keep the temperature between 1450 °C and 1650 °C to melt the steel.
After the melting process is done, we tap it into the ladle, and then the melted steel is drawn into the sand moulds that are deposited in the casting zone. Thus we obtain cast after the steel is solidified which then must be submitted to the next processes to get the design and desired shape of the customer.
The best Steel Casting Foundry in Mumbai, India, Sujan Industries, produces the demoulding of the castings by separating the moulding stand of the casting good. This operation is performed by a vibrating shake-out system. After separation, one part is casting good, which follows the remaining manufacturing process and the other part, the sand, is used for recycling. Now the demoulded steel goods are ready for the next step, shot-blasting.
The leading Stainless Steel Casting Manufacturers collect the casts in a basket and put them into a shot blasting machine. There, the rest of the sand attached to the casting is removed by projecting steel granules. The fettling shop at Sujan Industries is equipped with a hanger type KSBM that makes the shot blasting machines to contain the capacity of 300 kg. per batch.
6. Sleeves-feeders Cutting
So after the shot-blasting process is done, the goods are prepared for the sleeves-feeded cutting process. The entries and the channels designed are removed from the feeding system of the good.
7. Heat Treatments
Then the cast undergoes a special heat treatment to achieve the mechanical properties of strength, hardness, and toughness. At Sujan Industries, we have in-house facilities for standard heat treatments, Annealing, Normalizing, Tempering & Solution annealing.
Our heat treatment shop is equipped with a gas-fired HT furnace with 3 MT capacity, rapid quench facility with 30,000 litres capacity. The furnaces are calibrated as per API 6A standard. Also, our gas-fired salt bath furnaces have the capacity of Austempering 2.5 MP and Tempering 1 MT.
Now when the heat treatment is done, the products pass to the fettling processes, where the existing burrs and excess material from castings on the workpiece are removed.
9. Quality Control and Inspection
At Sujan Industries, the apex steel casting manufacturers in Mumbai, India, we ensure that all the casting processes are performed maintaining specific quality standards and procedures like dimensional and visual inspection, hardness & NDT testings etc. These are done to ensure that the end products are of top quality and satisfactory. We also carry out the specific testing requirement’s given by our esteemed clients.
Then, the entire manufacturing process of steel casting, at Sujan Industries, ends with the machining of the castings to get the final shapes and tolerances as per the requirements of the customers. At machining operations, we perform turning, milling, drilling, and balancing. Our in-house machining shop is equipped with leading-edge apparatus like CNC Machine, VMC Machine, Drill Machine, Lathe Machine, etc. with maximum capacity.
There are various types of testing done to ensure the best quality of steel casting products. At Sujan Industries, we assure the best quality products with the following facilities.
Chemical Testing Facilities :
As the best steel casting foundry, the quality of our products is checked in Shimadzu spectrometer, which has 24 elements with a Nitrogen channel. Also, we have Master samples for carbon steel and alloy steel from BAS. These processes are done to ensure the best quality product to our clients.
Physical Testing Facilities:
Depending on the chemical composition and heat treatment, the physical properties of the cast steel are gone through significant changes. According to the intended application, the properties are selected to match the performance requirements. The properties are as follows :
Hardness:The carbon content confirms the hardenability of steel.
Strength: Higher carbon content and hardness makes the steel strong.
Ductility: Lower carbon content and low hardness provide higher ductility to the steel.
Toughness: More ductility is linked to better toughness of the steel. Toughness is adjusted by adding alloying metals and heat treatment.
Wear Resistance: The resistance of the casting steel to friction and use is increased by adding alloying elements like molybdenum and chromium.
Corrosion Resistance: Cast steel can resist oxidation and rust just like wrought steel. High- alloy steel with higher levels of chromium and nickel are great at resisting oxidation.
Machinability: The machinability of the casting steel depends upon the hardness, strength, thermal conductivity, and expansion.
Weldability: The chemical composition and heat treatment are the primary influencers of the weldability of casting steel.
High-Temperature Properties: Casting steels that operate in high temperatures, can experience degradation of mechanical properties and early failure due to oxidation, hydrogen damage, sulfite scaling, and carbide instability.
Low-Temperature Properties: At low temperatures, the toughness of the cast steel is greatly reduced. So alloying and specialized heat treatments are applied to improve a casting’s ability to resist loads and stresses.
As the top steel casting foundry, Sujan Industries produces and delivers the best quality stainless steel casting products to the Indian Railway sector and looking forward to expanding its business in both Indian & overseas market. We also provide customized casting products according to our client’s requirements.
So if you’re looking for the best quality steel castings Get in Touch with us and let’s expand your business together!