Casting, Forging & Processing

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Casting Methods

Sand casting: Casting method characterized by the use of sand as a mold material.Sand casting is one of the most common methods can be used for both short- and long-run productions.

Vacuum casting: Is a type of sand casting. The advantages of vacuum casting process is that it improves casting quality, gives a smooth surface of the casted product as well that the mold hardness is high and uniform. Production size is ranging from 1,5kg to 10 000kg and production capacity of 1,500 tons per month.

Coated sand casting: Is a type of sand casting. Production size is ranging from 0,5kg to 150 kg.

Resin sand casting: Is a type of sand casting. Since Resin sand mold is very hard and solid, and it has smooth surfaces, the resin sand casting has more accurate dimensions and better surface smoothness, and less sand residual and casting defects on the surfaces and inside.

Investment Casting: Investment casting is a manufacturing process in which a wax pattern is coated with a refractory ceramic material. Once the ceramic material is hardened its internal geometry takes the shape of the casting. The wax is melted out and molten metal is poured into the cavity where the wax pattern was. The metal solidifies within the ceramic mold and then the metal casting is broken out. There are two types of investment casting, Water glass precision & Silica Sol.

Water glass precision casting: The advantages of this method is smooth surface and less surface and inside casting defects. Suited for engineering parts, automotive parts, eletric power grid accessories and train accessories. Production size ranging from 0,05kg - 250kg and a production capacity 650 tons/month.

Silica Sol casting: The advantages of this method is very smooth surface and less surface and inside casting defects. The process is suitable for material such as carbon steel, low alloy steel, strainless steel, cast iron, cast copper and aluminum. Production size ranging from 0,001kg - 50kg.

Lost-Foam casting: it is similar to investment casting except foam is used for the pattern instead of wax. 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.

Die casting: Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. Advantages of die casting: excellent dimensional accuracy, smooth cast surfaces and reduces or eliminates secondary machining operations

Forging Methods

Drop Forging: Drop forging is a forging process where a hammer is raised and then "dropped" onto the workpiece to deform it according to the shape of the die. Advantages: reduced chance of voids, better fatigue resistance,improved microstructure,continuous grain flow, finer grain size and greater strength.

Press Forging: Press forging works by slowly applying a continuous pressure or force, which differs from the near-instantaneous impact of drop-hammer forging. The main advantage of press forging is its ability to deform the complete workpiece.

Mechanical Processing

APe has access to a professional bridge shell machining production line, CNC lathes, ordinary lathes, planer, grinder, milling machine, machining center, large and small processing equipment. All of the mechanical processing equipment can meet the requirement of most parts of the machine.

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