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Castings

Cast Part’s Components & Assemblies
 

ENGINEERING

Engineering being our core any project undertaken, may it be a simple component or a complex assembly, flows through our following engineering proficiencies to achieve techno-commercial finesse in the array of Cast Part’s components & assemblies.
ENGINEERING EXPERTISE FOR COST EFFECTIVE PRODUCTS

Our comprehensive and practical knowledge of various Metallurgy, Casting Standards and processes such as Sand Cast...ing, Gravity Casting, Pressure Die Casting, Investment Casting and Shell Molding enables us to select the most suitable combination of processes and machines that in turn achieves the most desirable Cost / Precision / Volume / Time efficiency matrix.

IN-DEPTH UNDERSTANDINGS OF CLIENTS' REQUIREMENTS

Having penetrative abilities to understand clients' product key attributes, its functional requirements & desir...ed specifications, we contemplate on vital process parameters such as Grain Size and Shape,Strength, Permeability, Collapsibility, Reusability, Sand Conditioning, Metallurgical Formulations of Binders, Additives, Moisture Content etc. and appropriately design customized development and manufacturing plans to achieve an optimized techno-commercial product.

HANDLING INTRICATE AND ADVANCED JOBS

Our core competencies are in handling Castings having intricate Shapes & Complex Profiles including... Non-Symmetrical ones, Odd Sizes, Thin walled sections with Close Tolerances and Geometric Accuracy of various types of Ferrous, Non-Ferrous & other non-metallic raw materials.

PREDEFINED REMEDIES TO AVOID PROCESS DEFECTS

We are apt to envisage & encounter process defects and limitations such as Surface Discontinuities, Sand & othe...r inclusions, Porosity, Hot Tears, Shrinkage Cavities, Segregation and incorporate predefined remedies while designing the manufacturing plans.

VALUE ENGG, REVERSE INTEGRATION & DESIGN UPGRADE

We stand ready with our backward integration expertise and value engineering initiatives to revisit design param...eters and render optimum manufacturability solutions such as avoiding Shrinkage, Scrap, improving Cast Metal Yield, optimize Gating system design, Optimize Mold filling etc.

ENGINEERING SOFTWARE APPLICATION & INFO TECH

We provide comprehensive support in product design & development using advanced tools such as 3D Software, Fini...te Element Analysis (FEA) etc. for in-depth understanding of clients specifications & interfacing in further operations and subsequently assisting our Dies-Pattern Makers & Casting Foundries to profoundly comprehend the Job Profile leading to an optimized Casting production process thus adding value to clients' end product quality.

MANUFACTURING ENGINEERING & TOOLING SOLUTIONS

Our engineers have meticulous knowledge of manufacturing engineering, Tool design-development and prevent...ive maintenance systems supported by tool room for Castings Patterns, Dies, Jigs, Fixtures, Gauges and Special Inspection Devices to achieve mass production with consistent quality at minimal inspection.

ALLIANCE WITH TECHNICAL INSTITUTES & EXPERTS

Our strategic tie-ups with strong networks of consulting Technical Experts, R&D Institutes and laboratori...es dedicated to Foundries & Casting Industry assist us in enhancing our competencies.

ALLIED PROCESSES , ASSEMBLY ENGG. & TOTAL SOLUTIONS

Our post-manufacturing and supportive activities like Surface Treatment, Heat Treatment, Final Machining & oth...er allied processes and assembling, added with customized packaging makes us a Total Solution Provider to our Clients.

MANUFACTURING

Manufacturing & foundry set ups with our associated production units, vendors & subcontractors for castings comprises of…

SAND CASTING FACILITIES 

  • Induction and Cupola Furnaces
  • High Speed Intensive Sand Mixers
  • Hand and Machine Molding set ups
  • Fully Equipped Pattern Shop
  PRESSURE & GRAVITY DIE CASTING FACILITIES 

  • Melting cum holding furnaces
  • Pressure die-casting machines of various tonnage capacities
  • In-house post die-casting cleaning facility
  • Gravity die casting machines set-ups of various capacities
  • Consulting Die Shops to make complex dies, fixtures and gauges etc
  INVESTMENT CASTING FACILITATES 

  • Wax Injection Presses: fully automatic and semi-automatic
  • Shell Room: Centrally air-conditioned and humidity controlled with modern equipment
  • Melting shop with medium frequency induction furnaces
  • Die Shop to make complex dies, fixtures and gauges etc
SHELL CORE CASTING PROCESS FACILITIES  

  • Semi-automatic 4 station shell molding machines.
  • Shell Core making with automatic vertical / horizontal Shell Core Shooters
  • Melting shop with medium frequency induction furnaces.
  • Shell Room: Centrally air-conditioned and humidity controlled with modern equipment.
  • Die Shop to make complex dies, fixtures and gauges etc.
  CONSULTING R&D INSTITUTES & TESTING LABS DEDICATED TO CASTING   

  • Metallurgical Laboratories for chemical & physical properties inclusive of:
    • Spectro Analysis
    • Radiography
    • Liquid Penetrant Testing
    • Ultrasonic Testing
    • Magnetic Particle Inspection, etc.
  • Other Laboratries:
    • Sand Testing Facility
    • Spectrometer, Image Analyser
    • Permeability Test
    • Grain Size
  • Metrology Lab (having advance Instruments like CMM)

We process raw materials of various International Standards like DIN, BS, ASTM, EN, JIS, ISI etc.

Non-Ferrous Metals 

  • Copper & its Alloys
  • Brass
  • Bronze
  • Gun Metal
  • Zinc
  • Aluminum & its Alloys
Ferrous Metals 

  • Grey Cast Iron
  • S. G. Iron
  • Alloy Steel Casting
Specialty Metals 

  • Manganese based Steel Casting
  • Stainless Steel Castings in various grades

As a part of our total solutions approach, we also offer auxiliary and allied processes encompassing…

  • Finishing Operations: Fettling, De-burring, Hand Grinding, etc to finish the casting for further processing
  • Surface Strengthening: Shot Blasting, Shot Peening, Sand Blasting, etc
  • Heat Treatments: Hardening, Stress Relieving, Normalizing , Tempering / Annealing, Spherodising, Induction Hardening, Plasma Nitriding etc
  • Machining Operations as per the design specifications (Link to Machining Supplementary Processes)
  • Surface Finishing: Polishing, Buffing, Electro Polishing, etc
  • Surface Plating / Coatings: Painting, Zinc Plating, Nickel Plating, Chrome Plating, Powder Coating & Anodizing in different qualities / colors etc

All our products are manufactured in adherence to our quality policy & work system manuals. Please visit our quality page & work manuals for an in depth understanding of our procedures & systems.

Additionally, quality procedures specific to our casted components manufacturing are…

  • Typical testing & inspection inclusive of raw material & castings: Chemical composition and physical properties, microstructure, tensile test, radiography, hardness test, liquid penetrant testing, fluorescent powder test, ultrasonic testing, magnetic particle inspection, etc are performed as per the desired specifications
  • Specialized Mechanical Testing: Shock resistance test, creep strength test, eddy current Inspection, pressure leak test, surface roughness tests and salt spray testing are performed as per the desired specifications
  • Other specific tests for Sand quality: Moisture content, clay content, grain fineness, permeability, strength, refractoriness, mold hardness
  • Other tests such as Testing of pattern waxes, binders and binder formulations
  • Additional customized & comprehensive quality tests as per client drawings / specifications inclusive of accurately designed inspection gauges and devices
 

PRODUCTS & IT'S APPLICATIONS

Our value engineered & manufactured casted components & assemblies with focus on our client’s intent find their infinite customized applications across all engineering industries.
 

ACHIEVEMENTS

From simple sand & investment castings to thin wall pressure die castings, COREiNSPIRE has achieved its ingenuity to cutting edge products applied across various electrical, mechanical & automotive industries that highlight its core competencies.
Here are a few products of ferrous & non-ferrous metals, developed & manufactured by a variety of casting processes that underpin our achievements:

PRE CHAMBER FOR CYL.HEAD (INVESTMENT)

VALVE ROCKER ARM (PDC)

COMMUTOR END BRACKET (PDC)

BRAKE DISC (CI)

WHEEL HUB (CI)

LEAF SPRING HANGERS (SG)

OTHER PRODUCTS BY COREiNSPIRE