099948 86858

ayyappacastingpvtltd@gmail.com

Process



At Ayyappa Casting Pvt Ltd, our state-of-the-art production facilities, including advanced mechanized sand plants, CO2 moulding processes, and high-efficiency induction furnaces, are designed to ensure precise casting, superior surface finish, and dimensional accuracy for every product we manufacture.

SAND PLANT

    At Ayyappa Casting Pvt Ltd, Mechanized sand plant with the following facilities is in use to import good surface finish and dimensional accuracy
  • 300 kg intensive mixers — 2 Nos.
  • Correct quantity of return sand, additives and cycle time are controlled by PLC
  • Prepared sand compatibility is maintained between 39 to 43 bymeasuring return sand temperature and adjusting water addition.



MOULDING

  • For hand-moulding, CO2 process is used. The maximum size is 1300x13000x300mm
  • The moulding department is facilitated with
  • ARPA - 300-2 pair
  • ARPA - 200- I pair
  • Molding at Ayyappa Casting Pvt Ltd is the process of shaping liquid or pliable raw materials using a rigid frame, known as a mold or matrix. These molds are created using precise patterns or models, ensuring consistent quality and accuracy in every product manufactured.



PATTERN SHOP

    At Ayyappa Casting Pvt Ltd, we produce accurate patterns based on customer specifications, with in-house reworks ensuring dimensionally precise castings.
  • Patterns are made as per the measurements of customer drawings by outsourcing.
  • Pattern Minor Reworks done at Inhouse Only
  • A pattern is a copy of the object to be cast and prepares the cavity into which molten material will be poured during the casting process. They will repeatedly provide a dimensionally acceptable casting.


CORE SHOP

In the Core Shop at Ayyappa Casting Pvt Ltd, cold box core shooters and sand mixers are used to produce high-quality cores, ensuring precision and structural integrity in each casting.
  • 5kgs capacity cold box core shooter machine-9Nos
  • Core Sand Mixer
      1) 100kg Sand Mixer -4Nos
      2) 50kg Sand Mixer -2Nos
  • CO2 & air setting oil process are undertaken



METALLURIGICAL

Ayyappa Casting Pvt Ltd uses advanced metallurgical equipment, including C.E. meters and spectrometers, to ensure precise material composition and quality control before casting.
  • C.E meter is used (Suyash make) on the platform
  • Bruker Q2 ION make table top spectro meter is used to check 19 elements before pouring for various grades
  • Binacular inverted microscope with attached image analyser is used to check the micro structure.
  • Immersion pyrometer is used to check the metal temperature (suyash make).



MELTING

    In Ayyappa Casting Pvt Ltd' melting process, induction furnaces and a fume extraction system ensure precise temperature control and high-quality metal handling for consistent castings.
    Induction Furnace:
  • 650 HZ 1300 KW dual track plus medium frequency induction furnace.
  • 2 Nos 1Ton crucibles are in operation
  • Fume extraction system employed connected with venturi scrubber
  • Liquid metal is handled by ladle handler (300 kg T spout ladles).
  • The metal is transferred to moulds using mono rail systems

MELTING

Induction furnace is designed for rugged use and high-power density melting. This concept in mid-size furnaces has a body constructed of heavy cast refractory top and bottom sections with stainless steel reinforcment, providing a strong and rigid support for the heavy-duty, copper power coil and the working lining. It is ideal for medium-sized installations.

METALLURIGICAL

We offers the largest selection of metallurgical briquettes for use in cupola furnaces. Briquettes containing Silicon Carbide, Fluorospar, Coal, Charcoal are available in different sizes and shapes for precise additions to your charge. Carbon/Coal replacement briquettes are also available to reduce foundry coal, provide operational benefits and significant cost savings. Custom briquettes can also be developed to meet your specific needs.

METAL PORNING

The most MODERN & ADVACED, High-tech INNOVATIVE equipment designed to perform very efficiently. Most suitable machine for liquid metal transfer from one place to other very Quickly & safely. It is also used to collect metal from the melting furnace and to do SG Iron treatment near destination. The operator can operate the machine by radio remote control unit from a safe distance. The machine travels on the floor level & has SIX axes movement for easy maneuverabilityd.