Casting & Forging Parts

Sand Casting, or sand metal casting, is a process using sand and binder as the molding material to produce metal castings. A Metal sand casting is produced by placing a pattern (tooling) with a gating system in sand to create a mold. The pattern is then removed and liquid molten metal is poured into the mold cavity. Once the metal cools, the sand mold is broken away from the part and the casting is cleaned. Metals cast using the process include tin, cast iron, aluminum and steel, as well as copper and bronze and can be casted with various degrees of complicated configurations. The process is considered an economical option because it requires less technology and cost.

Investment casting is an industrial manufacturing process used to create complex industrial shapes and parts. It is also known as lost-wax casting and is an old technique for forming small (steel upto 600 lbs and Al. upto 60 lbs) metal casting.

In the process, a wax pattern of the part is created and literally number of these wax patterns are attached to the same sprue. This is called a tree. The tree is then dipped into a slurry compound several times before they sprinkle the tree with a sand-like abrasive material (ceramic). This is called the investment. Once the investment (mold) is thick enough, it is preheated to remove the wax from the mold and mold is sintered, then molten metal is poured in the mold to form the casting. They allow it to harden and cool and finally they remove the shell and cut off the cast metal parts of the sprue. The investment casting process usually costs more per unit than die casting or sand casting but It can create intricate shapes that would be difficult.

Die Casting Formed in foundries via a process with the same name, Die castings. Die casting works fairly simply. First, metal is heated to molten stage. Then, this molten metal is forced into hollow forming shapes called dies, molds or die molds. by apply a high pressure that helps force the metal to conform to the shape of the die. Once it has satisfactorily taken on said shape, the metal is allowed to cool and harden. Sometimes, the die casting process is followed with secondary processes aimed to improve the quality of the casting in some way.

Typically, manufacturers perform die casting using one or more non-ferrous metals. Such metals include aluminum, bronze, copper, lead, magnesium, tin and zinc.

Forgings The forging process is to shape metal using localized compressive forces to pressure metal to undergo plastic deformation and an alteration of its grain flow. This compressing force is delivered via a hammer and anvil. Forgings have high structural reliability when compared to a cast component. There are no internal gas pockets or voids that could cause unexpected failure under stress or impact. Forgings are typically used in automotive and trucks, off-highway and agricultural machines, etc. for connecting rods, crankshafts, transmission shafts, gears, spike harrow teeth, etc.

There are two main forging methods: closed die forging and open die forging.

Open die forging capabilities are ideally suited for the production of large, simple shaped parts but are also suitable for custom designed components. Open die forging is performed between flat dies with no pre-cut profiles. Open-die forging can produce forgings from a few pounds up to more than 300,000 lbs. and 80 feet in length.

Closed die forgings require specially made dies for each component and are very common and cost effective for large production runs. Closed die forging pounds or presses metal between two dies (called tooling) that contain a pre-cut profile of the desired part. Parts from a few ounces to 60,000 lbs. can be made using this process. Some smaller parts can actually be forged cold.

Genau Komponente LLP reputed, exporter and supplier of an efficient range of Ferrous and Non Ferrous Forged Components (both open and closed die) and Castings (Sand, Pressure Die, Investment or Lost core Castings). We are able to offer the best casting and forging options in the industry through our network of certified partner foundries. Our product range includes products like Forged Parts, Forged Pipe Fittings, Forged Valves, Automobile Components, Automotive Forged Components, Flanges, Non-Ferrous Components, Electrical parts, Agriculture Parts and Machined Components.

Our products are designed and developed in compliance to international quality standards and offer superior performance and are trusted and relied upon by OEMs through out industry. These are widely used in Automobile, Power generation, water and waste water, oil & gas, hydraulic, construction and industrial equipment industries.

Features:

• Lightweight

• Resistance against corrosion

• Premium finish