Cast House
The Company has two oil-fired, fixed-hearth, reverberatory Melting-cum-Holding Furnaces with regenerative burners of bath capacities 6 MT each.
The Hot Top Casting unit is flexible to cast 6”, 7” & 9” diameter billets in alloys ranging from 1xxx to 7xxx series.
Molten metal treatment is carried out using Granular Flux in conjunction with “eco-friendly” nitrogen degassing. The presence of hydrogen gas in the molten metal is detected using a Gas detector. Further degassing is carried out, if required, prior to casting.
Composition is determined using Direct Reading Vacuum Emission Spectrometer.
‘On-line' modification (wherever required) and grain refining are carried out using Al-Sr and AlTiB / AlTiC rods respectively. These ensure fine grains and thus, uniform strength along the length of each profile.
The Electrical Homogenizing Furnace is suitable to homogenize billets in various alloys with a temperature control of ± 5°C, a pre-requisite for good homogenizing. Homogenizing of the billets ensures uniform mechanical properties – hardness, UTS, Yield Strength, percentage Elongation etc. besides offering excellent surface for finishing operations such as anodizing, powder coating, electro-colouring, etc.
Extrusion Shop
With the 3 Extrusion Press lines – 2700 MT & 1620 MT (UBE, Japan) and 1250 MT (indigenous) – all PLC controlled, the Company is able to cater to the requirements ranging from miniature profiles up to large-sized Bars in Soft, Medium and High Strength Alloys. The arrangement for taper heating of billets ensures ‘ near-isothermal ' extrusions for achieving uniform property along the length of the extruded profiles / sections / bars.
Strength requirement of Rods / Bars and sections / profiles in Medium and High Strength Alloys for the engineering industry, auto sector and the Defence Sector, is very stringent and calls for separate solutionizing prior to age-hardening. We have the necessary solutionizing furnace with drop quench facility for this purpose.
Detonator Shell Stock, Forging Stock, Rivet Stock and Welding Filler Stock in Medium and High Strength Alloys are to be supplied in annealed condition. We have the necessary furnace for this purpose.
With the facility available for coiling and wire drawing, we are able to supply Armour Rods, Detonator Shell Stock, Rivet stock and Welding Filler Stock in various sizes.
With the Draw Bench and associated auxiliary equipment available to cold-draw Bars – round, square & hexagonal, we are able to cater to the exacting requirements of the automats which is the need of the hour to enhance plant productivity, a ‘ must ' in this era of globalization.
Tool Room
The Dies required to extrude profiles from the simplest to the most intricate in Soft, Medium and High Strength Alloys are designed ‘in-house' using 'mastercam'. Use of ‘mastercam' also assists in assessing the type of fit and the clearances required for the assembly of complementary profiles. The dies are machined on CNC Vertical Machining Centres.
The ‘in-house' heat treatment facility ensures good resilience in the Dies (manufactured out of one of the best available Hot Die Steels in the world) during ‘real-time' extrusion thus ensuring consistency in shape and size of the profiles.
The orifice corresponding to the profile shape is precisely cut on the wire cutting machine. The facility of nitriding ensures bright surface of the profiles, a ‘must' for subsequent finishing operations.
With the total infrastructure available in-house, we are able to manufacture the Dies for new profiles within 3 to 6 weeks from the date the profile dimensions and other requisite details are frozen.