Castings

Synergy offers complete technical expertise and manufacturing solutions for sourcing Metal Castings from India which includes –

• Identify and assessment of foundries.
• Onsite technical and process audits
• Budgetary pricing, techno commercial negotiation, comparative analysis including SWOT analysis,
• Product development support including tooling design, process flow simulation.
• Process control
• Production quality assurance
• Onsite inspection and logistics.

Contact us with drawing and material specs. of castings you wish to
source from India, for non-obligatory feasibility report.

Types of castings:

1. Steel Castings  &  Iron castings from Green sand, Shell and No-bake process
2. Wear Resistant castings for wear parts.
3. Non-ferrous castings like Aluminium, Zinc, Bronze, Brass etc. from High Pressure die and gravity die processes.
4. Lost wax investment Castings
5. Centrifugal Castings
6. Lost Foam Castings

Conforming to international standard like IS, ASTMA, ISO, DIN, BS, JIS etc.

Castings are sourced from top class foundries having excellent in house process and quality control facilities like pattern shop, fettling shop, heat treatment, online chemical testing with spectrometers, complete physical and non-destructive test equipment.

All castings can be delivered in proof machined or fully machined on state-of-the art CNC turning centres and machining centres with excellent in-process and final quality control.

Synergy can assure independent quality by having samples from foundries analysed in accredited private laboratories and provide reports on chemical and physical properties of castings.

Steel Castings

Steel castings can be offered from sand & investment casting processes like carbon steel, wear and abrasion resistant castings, stainless steel, low and high allow steel, nickel base alloys upto 5000 Kgs per piece conforming to international standards like ASTMA 216, 217, 297, 351, 352, 487 etc.

Iron Castings

a)  Ductile Iron castings (SG Iron) with weights upto a few metrics tons per piece. These castings can be produces on High Pressure Moulding Lines like Disa, Sinto, as well as jolt squeeze machine moulding processes. Cores are cold core boxes made form core shooters using resin bonding like phenol-formaldehyde resin & isocyanate.  Large castings used hand moulding green sand processes.

b) Grey Iron Castings upto 1500 kgs per piece. Again using

Non – Ferrous Castings

In Aluminium alloys in materials like A336, A355, 356.2, a380, A384, A413 in sand and gravity castings and HPDC alloys like ADC6, ADC8, ADC10, & ADC12 in High Pressure Die Castings upto 4 Kgs on upto 1500 tons.

Zinc grade like Zamak2, Zamak 5, Zamak6, Zamak 7

Copper alloys like Brass  including lead free brass like C6802, Aluminium bronze grade like AB,AB2, Gun metal grades like C83300, C84400, C92220, etc.

More choices of efficient metal casting technologies

Shell Molded Castings

Varieties of shell molded castings in complex shapes resulting in minimum machining and excellent surface finish of 6.3 to 12 microns Shell molded castings can be of Iron, Carbon Steel, Manganese Steel, Low & High Alloy Steels and non-ferrous castings like brass, copper alloys, etc. conforming to international standards.

Lost Wax Investment for steel & few non-ferrous alloys      

By lost wax process in a variety of metals offering near net shapes and as-cast surface finishes from 60 to 125 RMS. Dimensional tolerances of +/- 0.15 mm per every 25 mm can be achieved.

Investment castings can be manufactured out of the following metals.

• Carbon steel investment castings in
• Stainless Steel investment castings in
• Duplex stainless steels
• Precipitation hardened stainless steels like 17-4 PH
• Copper based alloys like Gun metal, Phosphor bronze, leaded tin bronze, aluminum bronze, manganese bronze, etc.

Lost Foam Castings for Iron Castings

Lost Foam Process is similar to Lost Wax (Investment casting) process.

Lost-foam casting (LFC) is a type of evaporative-pattern casting process that is similar to investment casting except EPS foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold.

This casting process is advantageous for very complex castings that would regularly require cores. It is also dimensionally accurate, maintains an excellent surface finish, requires no draft, and has no parting lines so no flash is formed. The un-bonded sand of lost foam casting can be much simpler to maintain than green sand and resin bonded sand systems. Lost foam is generally more economical than investment casting because it involves fewer steps.