| Quality Policy |
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| Raw Material |
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Samples are immediately drawn as soon as the inputs like wax sand, liquid chemicals, refractories and metals arrive in our premises. These samples are analysised in our well-equipped testing labs where they are tested for their viscosity, mesh and alumina contents in sand, checking for iron particles and in refractories etc. Chemical testing of metal is also carried out at our premises for arriving at exact composition of the metal.
The Vendors are immediately asked to take back the substandard and rejected goods in replacement of correct supplies. |
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| Process |
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At each and every stages of production quality control checking by our qualified technicians are being carried out minutely.
Wax preparation with proper mixing to get hardness and to ensure that the same is melted at certain temperature.
Slurry prepation: Viscosity checking and proper mixing of Zercon Flour and Silica Solution and ensure stirring for the stipulated level of duration.
Each wax pattern is inspected for correct formation and breakages. Each pattern is individually checked and unwanted
partision are removed.
While assessmbling the pattern also proper checking is done. Depending on components 8 to 10 coatings are done to prepare the shells. On each occasion of coating proper checking is carried out and each shell is also checked and sand particles, dust and other particles are removed. Cracked shells are immediately destroyed.
Before pouring the metal in liquid condition, it is tested in lab for chemical composition, for arriving the quality of the metal etc. if the liquid is found of substandard metal then it is not used but converting it to ingots.
The finished pcs are individually checked for hardness, blowholes, dimension, etc. and corrective measures like annealing etc. are done to ensure quality of the finished goods. |
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| Details of Test Equipments |
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| [1] |
Pirou Meters for Metal Temperature |
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Hardness Tester |
| [3] |
Viscosity Cup |
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Multi Meter |
| [5] |
Set of Vernier Calipher |
| [6] |
Set of Micro Meter |
| [7] |
Surface Plate |
| [8] |
Micro Weighing Machines |
| [9] |
Carbon Sulpher Aparters |
| [10] |
Muffle Furnace |
| [11] |
Mini Oven |
| [12] |
Hot Plates |
| [13] |
Glass wares and Beakers |
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| Quality Policy |
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| Fine Diewax Casting Ltd. is an investment castings manufacturer, hence it is necessary to cater the castings of intricate shaper with precise tolerances as per IS: 11199:1984. The achieve this goal; it is unavoidably necessary to maintain strict quality controls throughout the manufacturing process. For executing this object, we have established a quality assurance programme in the plant. |
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| Q.C in Die Development |
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| After studying the product drawing or sample, die-design is carried out. To obtain the required dimensions of product of the end of process, it is necessary to add proper shrinkage allowances to each dimension. When the die is received from the die maker, it is entirely inspected from dimension point of view and surface point of view. If there is any rectification, it is sent back to the die marker. After rectification, it is again inspected to see, whether the suggested rectification is completed or not. After die-inspection, if the die okayed by Q.C. Department, then it is sent to the pattern moulding department for sampling process. |
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| Pattern Moulding Department |
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Here, from die-mould, the wax patterns are prepared; Those patterns are inspected from dimension points of view and surface finish point of view. The okayed patterns are (if necessary repaired to remove parting lines and flashed) sent to pattern Assembly department for assembly of patterns into a cluster with central sprue, pouring basin and gates. The size of Central Sprue, pouring basin, gate are determined by well-experienced and qualified persons to achieve best results at every time. The methoding is pre-determined in the form of drawing illustrating full above details. Subsequently, in actual production, this successful methoding is strictly to be followed.
Basically, in wax department, we are producing wax patterns from specially blended and formulated wax. That means, we are formulating different types of wax i.e. Paraffin, Montan wax, Rosin Wax, Microcrystalline wax and polymer etc. in particular proportion to gain such a blend as to give us a best wax patterns. The wax formulation is of prime importance. Whenever wax is prepared this formulation is strictly followed and records are documented. The reclaimed wax is also treated prior to reuse. The ashen content of wax blend is periodically checked. The Ash-content must not exceed the particular limit otherwise the surface finish of wax pattern may be affected adversely.
The wax pattern assembly is inspected as per methoding-drawing. If it is Okayed, then the assembly is sent to shelling department. |
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| Shelling Department |
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The pattern, assembly are hung in specially designed trolley used for shelling operation.
First, the assembly is washed by detergent power to avoid oil or kerosene over the patterns. Subsequently water rinsing is done to remove the detergent over the surface.
Then, shelling is done by applying coats refratory materials. Numbers of coats are succeeded to achieve the proper wall thickness. Number of coats, to be applied, quality of slurry to be used and other parameters are pre-determined and recorded in methoding drawing. A strict and continuous inspection is carried out to see that all these parameters are properly maintained.
In melting department various shells are awaiting for pouring in different materials and grades. Melting in-charge plans for various heats material wise. Heat schedule is fixed, then depending upon the chemistry of metal required, Ferro-addition and additives are kept ready as per pre-fixed schedule of heat. Chemical composition of scrap is very important and therefore, it is carefully checked in laboratory as the Ferro-addition is directly depends upon this. The pouring temperature, pouring rate and purring speed etc. parameters are of prime important and is pre fixed in methoding. During melting, inspection is carried out to see whether these parameters are strictly followed or not. Heat capon and test bar samples are taken heat wise, which are tested and inspected for metallurgical properties.
After pouring, the shells are allowed to cool down and subsequently, they are shifted to Felting department. |
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| Felting Department |
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Likewise, pattern assembly, the shelling operation is also carried out in a separate chamber, which is air-conditioned. This chamber must be air-conditioned is allow the shell is allow the shell to dry without cracking to grain sound shell with proper probability. For this humidity and ambient temperature of the chamber is conditioned and controlled.
After shelling operation is completed, the shells are allowed to dry finally for 48 hours. Then the dried shells are sent to De-waxing department. |
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| Diewaxing Department |
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| There are many methods to diewax the shells. The process of removing wax to generate the cavity is called "drawing operation". In our plant, we are using water-de-waxing system to diewax the shells. During the process, the temperature of water is of prime importance and hence this parameter is strictly controlled. After de-waxing, inspection is carried out to see that the shells are without cracks and damage. If repairable damages are there, they are repaired at the end of process. Afterwards, the shells are sent to melting department for metal pouring. |
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| Melting Department |
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| The Shell are knocked out to remove the coating to let the metal cluster be opened. The clusters are then inspected to see the rejections. After this visual inspections, the okayed castings are cut from the gates by cutting and welding, pneumatic grinding, shot blasting, welding are used to get the final casting. The final castings are inspected dimensionally. The okayed castings are sent to dispatch department. Here, prior to packing, if necessary the castings are stained with oil avoid rusting over the surface. |
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| Quality Reports |
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| Strict quality inspection is carried out throughout the process to see that all process parameters are maintained. Reports wherever necessary are also documented. Following are the reports of Q C inspections are documented. |
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| [1] |
Die Inspection Report : This report is permanently documented and if demanded by customer, the copy is given to him otherwise as a general practice, this report is not given to customer. |
| [2] |
Wax Pattern Inspection Report : This report is also documented batch-wise and it is not issued to customer. This is only for our process controls. |
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Methoding System : In this, in form of drawing, the assembly details, coating, cycle, melting, parameters are documented. This is never allowed to let the customer know in any cases. It is a policy of management. |
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Shelling Schedule : In this, number of Coats, Drying hours, viscosity of the slurry, humidity etc. are recorded to see the process parameters. This is also not for customers. |
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Head Reports : This report for melting department to record the process parameters like Ferro-additions, melt temperature, pouring temperature, pouring speed, pouring rate etc,. This is not for customers. |
| [6] |
Final Casting Inspection Report : This report is documented batch wise and one copy is always given to customers with invoice. |
| [7] |
Sample Casting Inspection Report : This report is for the sample castings only. First the samples are given to the customers for their approval and after receiving a written approval, the actual production is taken. One copy is always issued to customer for approval. |
| [8] |
Test Certificate : This is specially given with authentic guarantee for chemical composition and other metallurgical properties. |
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| Moreover, these following tests are carried out on customer's demand and at customers' cost only. |
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| [1] |
Radio graphical Test |
| [2] |
Dye Penetration Test |
| [3] |
Pressure Testing of Castings |
| [4] |
Acid Picking of Castings |
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| In general, Fine Diewax Casting Ltd. is a company well equipped with metallurgical labs, instruments and technical staff with know-how to cater the investment casting as per IS: 1199:1984 Class II, Table II. |
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