Manufacture
Molding
The casting process begins with designing the parts in a digital environment using the 3D solid modeling method. During the modeling phase, detailed analyses are conducted considering manufacturing precision and technical requirements. These digitally prepared models serve as a reference for the molding stage.
In the mold production process, high-precision molds are prepared using fully automatic carbon dioxide molding machines. The sand to be used is selected based on the surface quality, dimensional accuracy, and durability requirements of the cast part. Accordingly, suitable sand is chosen within the 40 to 100 AFS range and mixed with carbon dioxide resin to achieve a homogeneous structure.
Melting
The steel used in the production process is melted at high temperatures in modern furnaces equipped with advanced technology, making it ready for processing. These furnaces reach approximately 1500°C, ensuring that the steel becomes fully liquid. The regenerative system used in our production line optimizes energy consumption, providing an environmentally friendly melting process. In this way, an efficient production process is achieved while minimizing environmental impact in line with sustainability principles.
Foundry
Analysis
Before starting the casting process, the chemical composition of the material to be used is analyzed in detail with an optical spectrometer. Based on the results of the examination, necessary element additions are made to ensure that the material acquires the desired mechanical and physical properties. After the alloy is prepared to meet the specified standards, the casting process begins, and the material is poured into the molds in a controlled manner, completing the shaping process.
Heat treatment
After casting, the materials, which are cleaned of burrs and surface roughness, undergo a heat treatment process to enhance mechanical strength and surface protection. During this process, the materials are heated at controlled temperatures to optimize their internal structures and achieve the desired mechanical properties. Heat treatment is an advanced engineering method that imparts properties such as strength, hardness, toughness, and wear resistance to metals and alloys, which are not naturally present in their original state. This significantly increases the performance and service life of the produced parts.
Quality control
Products that have undergone heat treatment are subjected to a meticulous quality control process before shipment. Various tests and analyses are conducted by experienced engineers to verify the compliance of the products' mechanical and chemical properties with the established standards. Parts that successfully pass the measurements and durability tests are carefully packaged after the final checks and are made ready for shipment to customers. This process is carried out with precision to guarantee the reliability and service life of the products.
Sand preparation
The sand preparation process involves the careful preparation of the sand material used in the production of casting molds and core boxes. At this stage, the sand mixture is prepared according to specific technical criteria to ensure high surface quality and durability in the casting. The materials used include sand particles as the main component, while a mixture of clay and water acts as a binder to enhance the stability of the sand. Additionally, special chemical additives used in the process optimize the mold's strength and gas permeability, helping to achieve flawless casting.
Core shop
The core shop is a critical production phase where molten metal is poured into pre-prepared sand molds to shape the material. During this process, the high-temperature liquid metal is poured into the molds according to specified technical parameters and subjected to a homogeneous cooling process. The cast parts, which cool in a controlled manner, are then allowed to rest in order to minimize internal stresses. Once sufficient hardness is achieved, the sand molds are broken and cleaned, and the resulting raw material is prepared for subsequent processes. This stage ensures the production of high-quality castings while maintaining the mechanical properties of the material.
Cleaning and Machining
The cast parts removed from the sand molds have a naturally rough and burr-filled surface. Therefore, the machining and cleaning phase is crucial to improve the surface quality of the material. In this process, mechanical and chemical cleaning methods are used to remove unwanted protrusions, casting burrs, and other defects from the surface. As a result, the parts become suitable for further machining, both aesthetically and functionally. This phase is an important production step that ensures the final product meets precise tolerances and high-quality standards.