Moulding Process

Green Sand Moulding Process

Green Sand Moulding

Applications

  • Ideal for cast iron (CI) and SG iron castings, particularly in small to medium batch quantities.
  • Hand Moulding: Used for small batches where flexibility in design and manual craftsmanship are essential.
  • Machine Moulding: Preferred for large batch quantities, offering greater consistency and productivity with our ARPA 300 moulding machine.

Process Overview

  • A mixture of sand, clay, and water is prepared to form the mould.
  • Patterns are pressed into the sand mixture, creating a cavity for casting.
  • The moulds are assembled, and molten metal is poured into the cavity to create the final product.

Pros

  • Cost-effective for both small and large production runs.
  • Fast mould preparation, reducing lead times.
  • Reusable sand lowers material costs.

Cons

  • Limited to medium precision tolerances.
  • Surface finish may require additional post-processing.

CO₂ Moulding Process

Applications

  • Ideal for large castings that demand robustness and dimensional stability.

Process Overview

  • Sand mixed with sodium silicate is packed around a pattern to create the mould.
  • The mould is hardened by passing CO₂ gas, which reacts with the sodium silicate to solidify the mould.
  • Molten metal is then poured into the rigid mould cavity to form the casting.
Green Sand Moulding

Pros

  • Perfect for producing heavy and intricate castings.
  • Provides moulds with excellent strength and high dimensional accuracy.
  • Simple and fast hardening process ensures efficiency.

Cons

  • Limited reusability of sand, leading to higher material costs.
  • Higher material costs compared to green sand moulding.
  • Gas evolution during casting may require controlled ventilation.

Shell Moulding Process

Green Sand Moulding

Applications

  • Ideal for castings requiring high precision and superior surface finish.
  • Especially suitable for complex and thin-walled designs.

Process Overview

  • A heated metal pattern is coated with a mixture of sand and resin binder.
  • The heat cures the resin, forming a thin, rigid shell around the pattern.
  • The shell mould is then removed, assembled, and filled with molten metal.

Pros

  • High dimensional accuracy and excellent surface finish.
  • Reduces the need for extensive machining and finishing.
  • Well-suited for small to medium-sized complex castings.

Cons

  • Higher tooling costs compared to other moulding methods.
  • Limited applicability for very large castings.

Choosing the Right Process

Batch Size

Whether it’s a small, medium, or large production run.

Casting Size & Complexity

From simple parts to highly intricate designs.

Material Requirements

Tailored specifically for CI and SG iron castings.

Customer Specifications

Considering factors like precision, surface finish, and cost-efficiency.

Why Choose Mangesh Alloys?

Advanced Equipment

Our state-of-the-art moulding machines and precision tools guarantee consistent, high-quality results.

Expertise Across Processes

With extensive experience in a wide range of casting processes, we ensure the best approach for every project.

Focus on Quality

Every casting undergoes a thorough inspection to meet the highest standards of quality and precision.

Cast Iron

High-Quality Casting Solutions for Every Industry

At Mangesh Alloys, we specialise in producing high-quality Cast Iron (CI) and Spheroidal Graphite Iron (SG Iron) castings that meet the most demanding industry standards. Utilising advanced induction furnaces and state-of-the-art moulding technologies, we offer castings in a broad weight range, from 0.5 kg to 300 kg. Our flexible casting methods, including green sand, CO2, no-bake, and shell moulding, ensure optimal metal grading, superior surface finish, and exceptional reliability. Whether you need small, medium, or large batch production, Mangesh Alloys is your trusted partner for precision castings tailored to your exact specifications.

Cast Iron Casting

Cast Iron (CI) Castings

Cast Iron (CI) remains one of the most versatile and widely used materials in the foundry industry, celebrated for its excellent mechanical properties and adaptability. At Mangesh Alloys, we produce CI castings renowned for their durability, strength, and cost-effectiveness, making them a trusted choice for demanding applications. Our CI castings are ideal for industrial applications such as automotive components, machinery parts, and construction equipment. Their ability to withstand high temperatures and provide exceptional wear resistance ensures reliable performance even under challenging conditions. With a commitment to innovation, we deliver tailored CI casting solutions that meet the highest standards of quality, precision, and performance.

Our CI Casting Processes

Green Sand Casting

Cost-effective for medium to large production runs, providing reliable, high-quality CI castings.

CO2 Casting

Used for large, intricate castings that require superior strength and dimensional stability.

Shell Moulding

Perfect for applications where high precision and excellent surface finish are critical.

Our CI castings are designed for superior wear resistance, excellent machinability, and high thermal conductivity, making them a go-to choice for a wide array of industries.

Spheroidal Graphite Iron Casting

Spheroidal Graphite Iron (SG Iron) Castings

Spheroidal Graphite Iron (SG Iron), also known as ductile iron, offers superior strength, ductility, and wear resistance compared to traditional cast iron. SG Iron castings are ideal for high-performance applications in industries such as automotive, hydraulics, and power generation.

Mangesh Alloys produces SG Iron castings that combine the mechanical properties of steel with the castability of iron. We use advanced moulding techniques to ensure high-quality, consistent results:

Our SG Iron Casting Processes

Green Sand Casting

For small- to medium-sized SG iron castings with excellent strength and ductility.

No-Bake Casting

For complex designs requiring high dimensional accuracy and tight tolerances.

Shell Moulding

Ideal for producing SG Iron castings that require superior surface finish and fine details.

Our SG Iron castings offer exceptional tensile strength, impact resistance, and fatigue resistance, making them the preferred choice for demanding applications where performance is critical.

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