Our plant has its own foundry, which ensures a closed production cycle. We closely monitor the technological casting processes and adhere to high quality standards. This approach allows us to create reliable pumps and various parts that meet the highest requirements.

Have you ever wondered how various parts and molds are made of metal?

Casting process, molding line

Molding line, Kamyanka. The Head of Foundry, Oleksandr Moshnyagul.

The Head of Foundry, Oleksandr Moshnyagul, is always happy to share this information with our valued customers, offering valuable insights into the intricate world of casting and its associated processes, with a special emphasis on our molding line manufactured by Rei├čaus & Baumberg Maschinenbau GmbH. So, how is a metal part made and what is so special about this molding line?

Let’s begin,

Step 1: Preparation of the part. First, the designer designs the model taking into account the technological requirements. Using special devices, such as CNC machines and 3D printers, this model can be created and manufactured.

Step 2: Preparation of the metal melting mixture. Next, you need to prepare the cold-hardening compound that is needed to create the mold. It is for this stage that a molding line is needed. For this purpose, we use special quartz sand, which hardens with the help of casting resin and catalysts without the need for heating. This allows us to manufacture products with high precision and various complex shape elements, and also helps to obtain a smooth and even surface of the products without the need for additional processing. Using outdated technologies based on heating sand or adding refractory clay and water can lead to major problems, such as changes in the size and shape of the product, resulting in deformations or incorrectly formed parts.

Step 3: Create the mold. At this stage, you need to create the mold itself. To do this, take the part model created on the CNC machine and fill it with the molding compound. The model leaves an imprint in the sand, creating a cavity in the mold that matches the dimensions of the part.

Step 4: The casting process. Now it’s time for the most important part: first, the charge is calculated and prepared, which consists of the components needed for smelting. The charge is then melted at a very high temperature and poured into a pre-made mold. The molten metal fills the cavity and takes its shape to form the part.

Step 5: Cooling and solidification. After the metal is poured into the mold, the crystallization and cooling process begins. This process takes a little time, as the metal needs to be sufficiently cooled to become solid and retain its shape. If it takes a long time (depending on the metal), the mold can be placed in a special cooling chamber.

Step 6: Opening the mold. When the metal has completely cooled and hardened, it’s time to open the mold. First, the top of the mold is removed or the frame that held the molding sand is disassembled. This allows you to remove the finished metal part from the mold.

Step 7: Post-processing. After the part is removed from the mold, finishing and cleaning is required. This may include removing excess material, grinding or polishing to obtain a smooth surface, and may require painting or other finishing if necessary.

The manufacturing of metal products is a complex endeavor that relies on the expertise of skilled workers, the utilization of cutting-edge technologies, and a relentless pursuit of continuous improvement. These crucial factors work in tandem to ensure the production of high-quality products that meet stringent standards and exceed customer expectations.

We take great pride in our commitment to delivering excellence in every metal product we create. Our team of highly trained professionals possesses a deep understanding of the intricate processes involved in metal manufacturing. Through their meticulous craftsmanship and attention to detail, they transform raw materials into exceptional finished products.

Continuous improvement is a driving force behind our operations. We consistently analyze and optimize our manufacturing processes to enhance productivity, and maintain the highest quality standards. Our commitment to staying at the forefront of industry best practices allows us to offer metal products that are not only durable and reliable but also environmentally sustainable.

To place orders or inquire about our metal manufacturing capabilities, we invite you to get in touch with our dedicated sales team. You can reach us via email at sale@kammash.com or by utilizing the convenient contact form on our website at https://kammash.com/ua/contact-us/. We are eager to assist you in bringing your metal product requirements to life and delivering solutions tailored to your specific needs.