Equipment

Production equipment

We use a production site with equipment for manufacturing industrial castings from cast irons, steels, aluminium alloys, copper and copper alloys from customer drawings.

The production cycle includes moulding in dry sand moulds using the AlphaSet process, core making, induction melting, gravity pouring, shakeout, cleaning, fettling, heat treatment, rapid laboratory inspection and machining.

Casting weight range — from several dozen grams to 2 tonnes.

Area	Equipment / tooling	Purpose	Main parameters
Melting area	Inductotherm induction melting furnaces	Melting of cast irons, steels, aluminium alloys, copper and copper alloys	Furnaces with a capacity of 1.5 tonnes
Melting area	Heraeus Electro-Nite temperature-control equipment	Temperature control of liquid metal during melting and pouring	According to the process requirements
Melting area	GNR SOLARIS optical emission spectrometer	Rapid chemical composition analysis of metal	Melt analysis before pouring
Melting area	Combustion Master CS carbon and sulphur analyser	Determination of carbon and sulphur by infrared absorption	C/S analysis for cast irons and steels
Moulding area	Omega moulding equipment	Manufacture of single-use dry sand moulds using the AlphaSet process	Cold-setting sand mixture / AlphaSet
Moulding area	SPARTAN moulding mixer	Preparation of moulding sand mixture	Capacity up to 10 tonnes of mixture per hour
Moulding area	Moulding area	Manufacture of moulds for medium and large castings	Mould size up to several metres, subject to drawing and process approval
Coremaking area	Core mixer	Manufacture of cores for complex hollow castings	Capacity up to 3 tonnes of mixture per hour
Coremaking area	Core tooling	Formation of internal channels, cavities, water jackets and complex internal surfaces	According to casting design
Sand reclamation	Omega moulding-sand reclamation equipment	Return and preparation of sand mixture for reuse	For the AlphaSet process
Shakeout	Vator 9LL mould shakeout area	Breaking the sand mould after cooling and removing the casting	According to mould weight and dimensions
Pattern and core-box tooling	Tooling manufacture on vertical CNC machines (partner)	Manufacture of patterns, core boxes and tooling elements	Plywood, plastic, aluminium and other materials according to purpose
Cleaning and fettling	Cutting and grinding equipment (fettling area)	Removal of the gating and feeding system, risers and process-related elements	According to the specific casting process
Cleaning and fettling	Amurlitmash shot-blasting machine	Cleaning casting surfaces from moulding sand, scale, burn-on and process contamination	For cast blanks after shakeout and fettling
Cleaning and fettling	Cleaning area	Final surface preparation, removal of fins, remaining gating-system material and local irregularities	Manual and mechanized cleaning
Heat treatment	Electric chamber furnace	Heat treatment of castings according to the agreed cycle	Working space approximately up to 1.5 × 1.5 × 1.5 m
Heat treatment	Termoskale chamber heating furnace	Stress relief, normalization, structure stabilization and other cycles according to material	Maximum temperature up to 1100 °C
Machining	Doosan NHP 5000 4-axis horizontal CNC machining centre	Machining of cast blanks, planes, holes, seating surfaces and datum surfaces	Working range approximately up to 600 × 600 × 600 mm
Machining	3-axis vertical machine with rotary table	Machining of parts from several sides in one setup	According to part dimensions and configuration
Machining	CNC lathes	Turning of bodies of revolution, bushings, flanges, covers and other cast parts	According to customer drawing
Machining	Universal lathes and drilling machines	Auxiliary, repair, drilling and preparatory operations	According to process needs
Laboratory	GNR SOLARIS optical emission spectrometer	Rapid analysis of the chemical composition of cast irons, steels, aluminium alloys, copper and copper alloys	According to calibrations and reference materials used
Laboratory	Combustion Master CS carbon and sulphur analyser	Determination of C/S by infrared absorption	For cast iron and steel control
Laboratory	Metallographic equipment	Microstructure analysis of cast irons and steels; control of graphite form, metal matrix and structural constituents	Microscopy approximately up to 100–150×
Laboratory	Colour metallography	Complex metallographic studies	Together with a partner company
Non-destructive testing	Radiographic testing (RT)	Inspection of internal casting defects	On site with accredited specialists
Non-destructive testing	Penetrant testing (PT)	Inspection of surface defects in castings and machined parts	On site with accredited specialists
Non-destructive testing	Ultrasonic testing (UT)	Inspection of internal discontinuities and wall thicknesses	On site with accredited specialists

Equipment in photos

All photos

Areas

Equipment by production area

Equipment	Purpose	Main parameters
Inductotherm induction melting furnaces	Melting of cast irons, steels, aluminium alloys, copper and copper alloys	Furnaces with a capacity of 1.5 tonnes
Heraeus Electro-Nite temperature-control equipment	Temperature control of liquid metal during melting and pouring	According to the process requirements
GNR SOLARIS optical emission spectrometer	Rapid chemical composition analysis of metal	Melt analysis before pouring
Combustion Master CS carbon and sulphur analyser	Determination of carbon and sulphur by infrared absorption	C/S analysis for cast irons and steels

Equipment	Purpose	Main parameters
Omega moulding equipment	Manufacture of single-use dry sand moulds using the AlphaSet process	Cold-setting sand mixture / AlphaSet
SPARTAN moulding mixer	Preparation of moulding sand mixture	Capacity up to 10 tonnes of mixture per hour
Moulding area	Manufacture of moulds for medium and large castings	Mould size up to several metres, subject to drawing and process approval

Equipment	Purpose	Main parameters
Core mixer	Manufacture of cores for complex hollow castings	Capacity up to 3 tonnes of mixture per hour
Core tooling	Formation of internal channels, cavities, water jackets and complex internal surfaces	According to casting design

Equipment	Purpose	Main parameters
Omega moulding-sand reclamation equipment	Return and preparation of sand mixture for reuse	For the AlphaSet process

Equipment	Purpose	Main parameters
Vator 9LL mould shakeout area	Breaking the sand mould after cooling and removing the casting	According to mould weight and dimensions

Equipment	Purpose	Main parameters
Tooling manufacture on vertical CNC machines (partner)	Manufacture of patterns, core boxes and tooling elements	Plywood, plastic, aluminium and other materials according to purpose

Equipment	Purpose	Main parameters
Cutting and grinding equipment (fettling area)	Removal of the gating and feeding system, risers and process-related elements	According to the specific casting process
Amurlitmash shot-blasting machine	Cleaning casting surfaces from moulding sand, scale, burn-on and process contamination	For cast blanks after shakeout and fettling
Cleaning area	Final surface preparation, removal of fins, remaining gating-system material and local irregularities	Manual and mechanized cleaning

Equipment	Purpose	Main parameters
Electric chamber furnace	Heat treatment of castings according to the agreed cycle	Working space approximately up to 1.5 × 1.5 × 1.5 m
Termoskale chamber heating furnace	Stress relief, normalization, structure stabilization and other cycles according to material	Maximum temperature up to 1100 °C

Equipment	Purpose	Main parameters
Doosan NHP 5000 4-axis horizontal CNC machining centre	Machining of cast blanks, planes, holes, seating surfaces and datum surfaces	Working range approximately up to 600 × 600 × 600 mm
3-axis vertical machine with rotary table	Machining of parts from several sides in one setup	According to part dimensions and configuration
CNC lathes	Turning of bodies of revolution, bushings, flanges, covers and other cast parts	According to customer drawing
Universal lathes and drilling machines	Auxiliary, repair, drilling and preparatory operations	According to process needs

Equipment	Purpose	Main parameters
GNR SOLARIS optical emission spectrometer	Rapid analysis of the chemical composition of cast irons, steels, aluminium alloys, copper and copper alloys	According to calibrations and reference materials used
Combustion Master CS carbon and sulphur analyser	Determination of C/S by infrared absorption	For cast iron and steel control
Metallographic equipment	Microstructure analysis of cast irons and steels; control of graphite form, metal matrix and structural constituents	Microscopy approximately up to 100–150×
Colour metallography	Complex metallographic studies	Together with a partner company

Method	Purpose	Main parameters
Radiographic testing (RT)	Inspection of internal casting defects	On site with accredited specialists
Penetrant testing (PT)	Inspection of surface defects in castings and machined parts	On site with accredited specialists
Ultrasonic testing (UT)	Inspection of internal discontinuities and wall thicknesses	On site with accredited specialists

We carry out the full casting production cycle — from mould preparation and metal melting to cleaning, heat treatment, laboratory inspection, non-destructive testing and machining. The specific process operations, inspection scope, machining requirements and documentation package are agreed with the customer at the drawing review stage.

Related sections

Industrial casting Castings and cast blanks from drawings and samples. Machining Machining capabilities for castings and blanks. Materials Cast irons, steels, aluminium alloys and copper alloys. Quality control Inspection methods, testing and documentation requirements.

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