Our Moulding 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.