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The permanent mold casting process Production process
Production Process
Raw materials reception :

Controlled purchases, costs and quality

All raw materials which go into the composition of parts are subject to rigourous sampling and controls. The materials are stored in an area where they are then loaded by an electro-magnet mounted on a gantry crane.
Melting :

Controlled melting

The metallic charge and the coke are weighed and controlled. They are then loaded via a skip into one of the two 8 ton-hour cold wind cupolas.

Stable and robust process

The metal produced is of a single grade, ie ENGJL 250, commonly called grey iron. Its chemical composition is controlled several times per hour with a spark spectrometer, for carbon and sulphur dosage by combustion, with a thermal analyser and an immersion pyrometer for temperature.
The metal goes through a holding furnace, with a 4 ton capacity, for homogeneisation of the metal, between melting and poring.

The metal is then distributed via 250 kg ladles into poring ladles of 80 kg.

Carrousels :

Capable production equipment

The NDC Foundry is equipped with 6 carrousels of 12 positions each, which allows a great diversity and flexibility of production, with small and medium series up to very high runs. The parts are produced by the permanent mold process, which is very rugged. The dies are very cheap and make the process very competitive, for grey iron parts. The parts are knocked out and then stored for cooling, before separation of the runners. The chemical composition of our iron, linked to a very fast and controlled cooling, make for a lamellar micrographic structure and an extremely fine quenched matrix.
Separation :

From little to big serie

Parts are then processed in a trummel for deburring and separation of runners and headers. Parts are sorted by reference.
Heat treatment furnaces :

Ferritisation heat treatment for a very good machinability

NDC Foundry has two furnaces, one of 2,5 tons/hr, and one of 3,5 tons/hr. The whole production goes through one or the other, and is submitted to a ferritisation treatment. The temperature is monitored and recorded at all critical steps of the treatment.
Shotblasting, grinding :

Really good surface after shot-blasting

Heat treated parts must then be rid of calamine that covers them, in our two shotblasting machines, and depending on products also go through a last deburring in a trummel.
6 semi-automatic grinders take care of the remaining flash. We also have a GARDNER surfacing machine, which allow us to grind flat parts.
Controls :
The production of each different part is naturally controlled regularly at each step, according to our surveillance plan, but a 100% control still takes place before packing. This is to maintain optimal quality at our customers and maximise their satisfaction. NDC Foundry can also offer magnetoscopic control on request. NDC Foundry has all he necessary equipment for measirung controls that customers may require.
Storage and shipping :
Parts are stored on the ground in our own plant. Parts can be packed in cardboard boxes, wooden boxes, stillages, and shipped in containers by lorry/truck, etc.
The permanent mold casting process Production process
  NDC Foundry - ZI du canal des Soeurs - France - 17300 Rochefort-sur-Mer - Tél +33 (0)5. 46. 82. 10. 10. - Fax +33 (0)5. 46. 99. 18. 76.

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