Industrial Foundry Casting Processes
At Knights Foundry, we use the alkaline phenolic sand process to produce high-quality ferrous metal castings. This allows us to achieve precision, dimensional accuracy, and superior surface finishes.
| Station | Mixing Capacity | Key Features |
|---|---|---|
| Station 1 | 20 tons per hour | Handles a wide range of casting sizes. |
| Station 2 | 10 tons per hour | High-volume production; up to 150 moulds per 24-hour cycle. |
| Station 3 | 10 tons per hour | Ideal for complex geometries. |
| Station 4 | 6 tons per hour | Versatile for diverse casting requirements. |
Our Sand Reclaim System
We believe in sustainability and efficiency, which is why we have invested in an advanced sand reclaim system. This system recycles and restores used sand, reducing waste and ensuring consistent quality in our castings.
- We mechanically break down used moulds to separate sand from residual binders.
- Our thermal treatment process restores the sand’s original properties.
- By reclaiming sand, we reduce environmental impact and lower production costs.
Our Casting Processes
Our casting techniques ensure defect-free production with enhanced durability. By using modulus-based casting calculations, we optimize solidification control, riser placement, and metal flow to produce high-quality ferrous castings.
- We use directional solidification to prevent shrinkage defects.
- Our risers are placed strategically to ensure proper molten metal feeding.
- Our gating system is designed for turbulence-free metal flow, ensuring superior surface quality.
Fettling Process
At Knights Foundry, the fettling process ensures that castings meet precise dimensional and surface quality requirements through cleaning, finishing, and inspection.
Casting Removal and Cooling
- Castings are carefully removed from the mould to prevent damage or distortion.
- Cooled uniformly to reduce residual stresses.
Gate and Riser Removal
- Excess metal from gating systems, risers, and feeders is removed using cutting torches, gouging processes, and grinding media.
- Precision cutting techniques ensure dimensional integrity.
Our Heat Treatment Process
To ensure strength, durability, and machinability, we offer advanced heat treatment processes. These processes refine grain structure, enhance mechanical properties, and ensure each casting meets the highest quality standards.
| Process | Description |
|---|---|
| Normalizing | Refines grain structure and ensures uniform mechanical properties. |
| Hardening | Increases strength and wear resistance through rapid quenching. |
| Annealing | Softens metal for improved machinability. |
| Tempering | Maintains hardness while reducing brittleness. |
Knights Foundry Inspection and Testing
All castings are inspected and tested to ensure adherence to prescribed standards.
3D Laser Scanning
High-resolution scanning ensures precise dimensional accuracy.
Ultrasonic Testing
Detects internal defects, ensuring structural integrity.
Radiographic Testing
Identifies porosity and inclusions using X-ray technology.
Magnetic Particle Testing
Detects surface defects using magnetic fields.