Melting

Melting of the metal is carried out in the induction furnace as per forging requirement. The grades are selected as per the required chemistry of the ingot. Heat is analyzed for necessary adjustments of various alloying elements made through additions of Ferro-Alloys. After casting, the mould is allowed to cool for a predetermined period of time before removing the ingot from the mould. Then the casted ingot is examined for surface defects and final chemistry before sending the same for forging.

Forging

Raw material (Forging Ingot) is heated up according to standard soaking time at required temperature. Upsetting and forging process is done to achieve proper reduction ratio, shape and size. Forged shape is cooled in Air/Pit according to grade requirement. Forging is dimensionally and ultrasonically examined in forged condition before sending it for annealing/normalizing.

Heat Treatment

Annealing/ Normalizing is done when a lot is ready. Temperature and soaking time is set. Heat treatment cycle is noted and adhered to according to requirement. For Hardening and Tempering, the consequent process is followed according to the grade in the heat treatment plant.

Machining

Forgings are sent to the machine shop if machining is required where they are proof machined or finish machined.Now after machining, these are checked dimensionally and physically again.

Testing

Hardness is checked with digital hardness tester and noted. Sample is cut after forging/heat treatment and checked for physical properties on universal testing machine and results are noted.Ultrasonic and MPT is done to ensure that forgings are defect free. Testing is done multiple times for physical and chemical properties to ensure ideal quality of material is achieved.

Dispatch

After following all the mentioned processes, the material is checked once again by the quality inspector. Colour Coding is done if required by the customer and every piece is stamped with an identification number for traceability. The products are then carefully packed and shipped to our happy customers.