Inspection Quality Testing

Quality Assurance and Testing at Mangesh Alloys

Ensuring Excellence
At Mangesh Alloys, quality isn’t just a commitment—it’s a standard that defines every step of our manufacturing process. With rigorous testing protocols and advanced technology, we ensure that every casting delivers exceptional performance, precision, and reliability.

Here's how we achieve excellence:

Quality Assurance
Raw Material Testing

Raw Material Testing

The Foundation of Quality

We partner with trusted suppliers and verify test certificates to ensure raw materials meet stringent quality standards.

Key materials like bentonite and coal dust undergo additional testing by our expert team before production begins, guaranteeing consistency and performance.

In-Process Testing

Precision at Every Stage

Melting and Metallurgical Testing

Temperature Control: Using a pyrometer, we maintain precise pouring temperatures between 1380-1395°C for Cast Iron (CI) castings, tailored to component size and specifications.

Chemical Composition:

  • CE Meter: Ensures accurate carbon and silicon levels.
  • Spectrometer Analysis: Provides detailed insights into all critical elements, enabling precise adjustments.
  • Microstructure Analysis: Examines the internal grain structure to confirm material grade and ensure superior casting quality.
In-Process Testing
Sand Testing

Sand Testing

Ensuring Mold Performance

Sand quality is essential for optimal mold performance. To maintain consistency, we conduct critical tests every 3 hours, including:

  • Compatibility Test: Assesses sand compatibility with molding requirements.
  • Permeability Test: Ensures proper airflow within the mold.
  • Green Compressive Strength (GCS) Test: Measures sand strength under compression.
  • Moisture Content Test: Verifies optimal moisture levels for molding.
  • Mold Hardness Testing: Ensures uniform hardness across molds using a mold hardness tester.

Final Product Testing

Delivering Perfection

  • Hardness Testing: Each batch undergoes hardness checks to meet customer specifications and ensure consistent quality.
  • Dimensional Verification: All castings are thoroughly measured for accuracy. For specific requirements, we provide Coordinate Measuring Machine (CMM) reports, ensuring compliance with technical drawings.
  • Tensile Strength Testing: Tensile strength evaluations are performed on a Universal Testing Machine (UTM) upon request, confirming the mechanical properties meet required standards.
Final Product Testing

Pressure Testing

Verifying Performance Under Pressure

At Mangesh Alloys, we perform rigorous pressure testing, including hydrostatic testing, to ensure our castings meet the highest standards of structural integrity and leak resistance. By subjecting components to specific pressure levels using water or other incompressible fluids, we verify their ability to perform reliably under real-world operating conditions. With testing capabilities ranging from 10 to 500 bar (145 to 7,250 psi), we ensure our castings deliver durability, safety, and unmatched quality for high-pressure applications.

Gray Cast Iron

Purpose

Hydrostatic testing is designed to:

Detect leaks in castings that may compromise performance.

Validate structural integrity to ensure the component can endure operating pressures

Confirm pressure endurance under real-world conditions, making it ideal for high-pressure and safety-critical applications.

Procedure

The casting is thoroughly inspected and prepared for testing.

Water or another incompressible liquid is introduced into the casting to eliminate air gaps.

The liquid is pressurised to a predetermined level, simulating the actual operating pressures the component will face.

The component is carefully monitored for leaks, deformations, or pressure loss to ensure it meets the required standards.

Gray Cast Iron
Gray Cast Iron

Testing Parameters

Hydrostatic testing is designed to:

Maximum Pressure: We test components up to 500 bar (7,250 psi) for high-pressure applications

Standard Range: Most applications are tested between 10 and 200 bar (145 to 2,900 psi), depending on the component's specifications and end-use requirements.

Why Hydrostatic Testing Matters?

Ensures leak-free performance for critical applications.
Validates durability and structural strength of castings
Provides confidence in safety and reliability under pressure.
Critical for industries like hydraulics, pumps, valves, oil & gas, and automotive, where components face extreme conditions.
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