EMC

EMC +Durable steel foundry

EMC

EMC +Durable steel foundry

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Steel Casting Cost Factors

Steel Casting Cost Factors

 

 5FFactors influencing steel casting parts price

 

1-Geometry and shape of part

Internal cavities, quantity and thickness of cores, thin walls, long parts, complicated shapes, more than one parting line requirement, non linear parting lines, reverse angles and nonsymmetrical parts and similar limitation will increase sand casting prices.

Mentioned complexities will increase casting defects such as cold lap, core replacement, flash, mismatch, raised core, deformation and other usual casting defects in result scrap rate will be higher than normal for these kind of parts.

   

 2-Alloy and alloying elements

Alloying element according to their effects and induced properties are used in steel. The alloying elements in order of value increment are silicon, manganese, Chromium, Titanium, molybdenum, nickel, niobium and vanadium.

Although manufacturers should spend more for melt treatment and production of  low carbon and special alloys.

The alloying element quantity and closed range of standards will also increase the prices.

  

3-Order quantity

Order quantity is effective in gating and risering design, molding material and process, pattern making costs.

    

4-Required Mechanical properties and heat treatment

Steels are heat treatable. Changing heat treatment process will change microstructure and mechanical properties of parts. Annealing and normalizing are usual heat treatment of steel parts that are used to homogenizing microstructure and decreasing solidification stresses.

In some cases to achieve required properties, multiple and costly heat treatments are used. For example normalizing, quenching and tempering are necessary in hardening cast steels. Depreciation of tools and furnaces in high temperature and related costs will increase the part price.

    

5-Requested tests according to safety and critical application

Safety and critical parts should produce under controlled processes and need more tests and qualifications. These kinds of tests are costly and will increase the prices.

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Zero Escaped Defect

Zero Escaped Defect

  

As we know in foundry in contrast of other industries because of wide range of effective parameters on quality, it will be very hard and sometimes impossible to control all parameters and processes. 

 

 In these situation workers experiences and skills have an important role in quality. Technical knowledge and process control should decrease the fluctuations to produce sound casting in large quantities. But even with various tools of process control and simulation, defects could be appeared.

 

Nowadays in foundries 1 to 5 percent scrap rate is accepted as the nature of foundry. Therefore to do not deliver defective parts to customers foundryman should do something. We called it "Zero Escaped defects" . It means that we are responsible to be sure that only sound and defect free parts will be delivered to customers.  Criteria for assessment of goal is returned parts rate. It should be near to zero.

 

Read more at http://www.emcasting.com/?en/pages/2/61/Zero-Escaped-Defect.html#YmS1sMWCcXr7k3kz.99
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EMC Productsٍ

Oil, Gas, Chemical and Petrochemical

 

Pump Parts

Casing, Impeller, Diffuser, Wear Ring, Shaft Sleeve, Stuffing box, Casing Cover

 

Valve Parts

Body, Bonnet, Gate, Cage, Plug, Stem Nut, wheel, Disk, Hinge

 

Petrochemical Parts

Tube Hanger, Tube sheet, Support,

 

Mining, Cement, Refractory and Tile

 

Jaw Crusher Parts

Ball Mill Parts

Vertical Mill Parts

Hammer Mill Parts

Reymond Mill Parts

 

Digging, loading and excavating machine Parts

Bucket Teeth, Adapter, Truck Link, Shroud, Side Cutter, Ripper teeth

 

General Machinery

Gear Box Casing, Cast Gears, Ring and …

 


Read more at http://www.emcasting.com/?en/pages/2/59/EMC-Products%D9%8D.html#Smcbx5KygmKWSYMX.99

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EMC Abilities

َAbilities

Casting plant, with the help of more than 50 skilled employees provide EMC the ability to supply premium quality casting from 10 Kg to 2000 Kg in materials from carbon steel all the way through to nickel base superalloys.

 

Low Alloy Steels

•High alloy Steels (Stainless, Heat, Corrosion and Wear Resistant)

•High Alloy Cast Irons (High Silicon Corrosion Resistant, Ni-hard, Ni-resist, High Chromium)

•Air melted Nickel and Cobalt Alloys

 

Low Alloy Steels

 ASTM A216 (WCB, WCA, WCC), ASTM A352 (LCB, LCC), ASTM A217 C5, 4140, 4340, 9840 and similar alloys

 

Alloy Cast Iron

 High Silicon Cast Iron (ASTM A518), Ni-resist Ductile Iron (ASTM A436), Ni hard and high Chromium ASTM A532

 

Stainless Steels  

 CA15, CA40, CF8, CF8M, CF3M, CA6NM, CB7Cu-1(17-4PH),AISI 321, Duplex and Similar alloys as ATSM standard

 

Heat Resistant Alloys  

ASTM A297 HK, HH, HP, HL, HN, Multimet (N-155), Incoloy 800, Inconel 625, 50Cr-50Ni Nb, FSX414

 

Nickel Base Corrosion Resistant Alloys

M35-1(Monel 400), N12MV (Hastelloy B-2), CW12MW (Hastelloy C-276) and Similar alloys as ATSM standard

 

 Wear Resistant Steels  

High Manganese (ASTM A128), Innovative Bainitic wear resistant steel (Hardness 44-48 HRC, 100 J Impact Resistance Energy)

 


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