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STEEL CASTINGS

Welcome to our steel casting manufacturing hub, where precision meets strength. Explore our diverse range of steel casting solutions, meticulously crafted to meet industry standards and your unique specifications. From alloy selection to final inspection, we ensure the highest quality at every step. Trust us to bring your vision to life with durable, reliable, and precisely engineered steel castings. Discover the excellence that defines us – your trusted partner in steel casting innovation.

PROCESSES:

Green Sand Casting

Green sand casting is a method that involves using a mixture of sand, clay, and water to create molds. The mold is created by packing the mixture around a pattern, which is then removed to create a cavity for casting. Molten metal is poured into the cavity, and the mold allows for the creation of complex intricate designs. After solidification, the sand mold is broken to retrieve the finished cast part. Green sand casting is cost-effective and versatile, making it suitable for parts in the automotive, machinery, and agriculture industries.

Chemical Sand Casting

Chemical sand casting, also known as no-bake molding, is a method using a chemically bonded sand mixture instead of traditional green sand. Chemically Bonded sand molds are created using a wood, metal, or plastic pattern. It involves packing a mixture of sand, resin, and catalyst around a pattern, and hardening it with a catalyst. This allows greater dimensional accuracy, finer surface finish, & reduced casting defects, making it apt for high-precision applications in industries like aerospace and defense.

Investment Casting

Investment casting, also known as the lost wax process, is a precision casting process that produces intricate, high-quality parts with excellent surface finish. It involves creating a wax pattern and coating it with ceramic slurry. The ceramic shell is heated to melt the wax, leaving a hollow cavity. Molten metal is poured into the cavity with complex geometry accurately. The shell is then shattered to retrieve the part. This method is used in industries such as power, aerospace, marine, and medicine.

ALLOY AND GRADES:

ALLOY NAME	MECHANICAL PROPERTIES	MATERIAL CHARACTERISTICS	APPLICATION INDUSTRY	EXAMPLE PART
Austenitic - Corrosion Resistance (Higher Nickel)
304 stainless steel	Tensile Strength: 515-690 MPa, Hardness: 70-92 HRB	Widely used, Ductility (low carbon content)	Food Processing, Kitchen	Kitchen sinks, Process equipment, Tanks
304L stainless steel	Tensile Strength: 485-655 MPa, Hardness: 70-88 HRB	Ductility (lower carbon for weldability)	Chemical, Oil & Gas	Process equipment, Heat exchangers
316 stainless steel	Tensile Strength: 515-690 MPa, Hardness: 75-95 HRB	Excellent Corrosion Resistance (with molybdenum)	Paper industry, Chemical processing equipment, Pharmerceutical	Propellers, Medical devices, Furnace parts
316L stainless steel	Tensile Strength: 485-655 MPa, Hardness: 75-95 HRB	Improved Weldability, Corrosion Resistance	Marine, Chemical	Marine components, Chemical vessels
201 stainless steel	Tensile Strength: 620-795 MPa, Hardness: 70-88 HRB	Cost-Effective (lower nickel), Corrosion Resist.	Construction, Automotive	Structural components, Springs
Duplex - High Strength, Duplex Structure
2205 stainless steel	Tensile Strength: 620-800 MPa, Hardness: 20-35 HRC	Resistance to Stress and Corrosion, Used for Welding	Oil & Gas, Chemical	Pipes, Pressure vessels
Martensitic - Heat Treatable, Moderate Corrosion
410 stainless steel	Tensile Strength: 450-655 MPa, Hardness: 70-85 HRB	Moderate Corrosion Resistance, Machinability	Aerospace, Firearms	Aircraft components, Mechanical part, bolts
PH - Precipitation-Hardened (By Ageing)
17-4ph	Tensile Strength: 725-930 MPa, Hardness: 30-45 HRC	High Strength, Precipitation- Hardened	Aerospace, Medical	Aircraft landing gear, Surgical instruments

Grades and Applications:

Grade	Application
ASTM A36	A widely used structural steel grade for general construction purposes.
ASTM A572	High-strength low-alloy structural steel used in construction and heavy machinery.
ASTM A500	Cold-formed welded and seamless carbon steel structural tubing in round, square, and rectangular shapes.
ASTM A992	A high-strength, low-alloy structural steel widely used in construction.
ASTM A516	Pressure vessel quality steel used in the construction of boilers and pressure vessels.
AISI 4140	A versatile chromium-molybdenum alloy steel used in various applications such as automotive, aerospace, and oil and gas.
AISI 1018	A low-carbon steel with good weldability and machinability, commonly used in shafts, pins, and rods.
AISI 1045	A medium carbon steel used in applications requiring higher strength and hardness.
ASTM A615 / A706	Grades of steel rebar used in reinforced concrete construction.
AISI 316	A stainless steel grade commonly used in marine environments and for food processing equipment.

Steel Castings:

Butterfly Valve Body

Stainless Steel Complex Manifold

Stainless Steel Flange

Stainless Steel Gear Set

Stainless Steel Impeller

Stainless Steel Valve Base

Steel Pump Housing

CNC Turn Mill Components

Valves and Pumps Components

Cylindrical Ball Fittings

Steel Housing

Steel Pump

PRODUCTS AND SPECIFICATIONS:

Here at Calmet, our goal is to manufacture and deliver products as per the requirements considering their specifications given at the time of ordering. It’s not about the details but we also incorporate and put in our expertise and capabilities to ensure the most superior quality products are delivered to the customer.

COMPREHENSIVE SOLUTIONS:

High Precision Machining

We continually invest in efficient equipment and technology, allowing us to offer state-of-the-art services at competitive prices.

Our facilities have made significant investments in robotics to increase automation and efficiency with the latest generation Machining Centers, HMCs, VMCs, VTLs and Special Purpose Machines

Real-time automation software provides instant access to planning, manufacturing, and data collection from the manufacturing floor.

Our expertise on the various alloys allows us to make recommendations to improve the processing quality without sacrificing quality and performance.

Component Assembly

We are an extension of the OEM production for several large corporations. We not only partner with our customers in supplying castings and components but also provide assemblies and sub-assemblies from our facilities.

Our experienced team assembles parts through several automated and modern welding techniques such as fusion welding, pressure welding, brazing and soldering. Using the correct techniques results in saving our customers money and time.

Our cross-trained staff combined with work cells create a flexible welding assembly environment that can support a variety of fulfillment options with optimum methods depending upon functionality.

Design & Engineering

Engineering design is the process of finding a solution based on objectives, constraints, prototyping, testing and evaluation.

Our experienced team of engineers assists with the design phase and prototyping to ensure that samples and materials deliver products with the required features and specifications for customers.

We work with customers to resolve metal issues and ensure proper design and construction. Brainstorming is an essential part of our design and development programs before a final solution is arrived at.

Our workshop provides samples with different dimensions, materials and specifications to meet the different requirements of our customers.

Specialized Treatment

We offer all sorts of treatments including heat treatment including normalizing, quenching, tempering, nitriding, carburization, annealing, induction hardening, burnishing and others.

We can also treat the surface of the products to achieve better properties or just for aesthetic reasons.

The company has expertise in sandblasting, painting, and electroplating for special finishes by zinc, nickel, Chrome, etc. in addition to hot dip galvanizing and thermal spray metalizing.

Calmet regularly reviews the Quality Key Performance Indicators to compare the performance against the preset standards for best outcomes from treatments.

3-STAGE QUALITY CONTROL & INSPECTION:

The quality assessment process with special testing equipment ensures only the finest products reach the buyers and customers.
Here at Calmet, all the employees receive in-depth training, guidance and potential elevation from the mentors or immediate managers who are always observant of the continuous progress and Lean philosophy (Kaizen).
This intensive process ensures that the employees are well equipped with the knowledge and work techniques as per their role in the organization.
This task and its needed output will be perfect if performed with thorough understanding. It's crucial for our quality department to look in and strictly advise on any necessary changes to be made to ensure scope of errors are minimized or removed.

Raw material

Immersion Spectrometer with 24 Elements
Sand Testing Facilities
Universal Tensile Testing Machine
Image Analyzer
On-line Mold checking Facilities

Dimensional

Coordinate Measuring Machine (CNC-CMM) – Range: 1m x 1m
Linear Measuring Machine (LMM) – Range: 1m x 1m
Profile Projector
Digital Height Gauge – Range: 1m
All kind of Inspection Gauges & Instruments

Specialized

Non-Destructive Test (X-ray)
Ultrasonic Test
Dye Penetrant Test
Hydro Test
Millipore Cleanliness Test
Static Balancing

CASE STUDIES – EXPERTISE DEMONSTRATION

Case Study 1: Oil & Gas Casting Development

In response to the growing demand for durable and high-performance components in diverse industries, our steel casting development team embarked on a journey to enhance efficiency and durability through advanced technologies. This case study highlights a successful project that showcases our commitment to innovation and excellence in steel casting.

Objective:
Our primary objective was to develop a steel casting solution that not only meets stringent industry standards but also exceeds performance expectations. The focus was on im

Methodology:

Material Selection: Thorough research led to the identification of an advanced alloy with superior mechanical properties, including increased strength and wear resistance.
Computer-Aided Design (CAD):Utilizing cutting-edge CAD technology, our engineers created intricate designs to optimize the casting process and enhance component performance.
Simulation and Prototyping: Advanced simulations were conducted to analyze the casting process, identify potential issues, and optimize parameters. Prototyping allowed us to validate the design and assess the feasibility of mass production.
Innovative Casting Techniques: Implementing state-of-the-art casting techniques, such as vacuum-assisted casting and precision molding, contributed to reducing defects and enhancing the overall quality of the steel castings.
Quality Control Measures: Rigorous quality control measures, including non-destructive testing and dimensional inspections, were integrated into the production process to ensure the highest standards of quality.

Results:

The developed steel casting solution demonstrated remarkable improvements in:

– Strength and Durability: The advanced alloy significantly increased the strength and wear resistance of the cast components, extending their operational lifespan.

– Production Efficiency: Implementation of innovative casting techniques reduced production time, enhancing overall efficiency and cost-effectiveness.

– Quality Assurance: Stringent quality control measures ensured that each casting met or exceeded industry standards, providing our clients with reliable and high-performance components.

Conclusion:

This case study exemplifies our dedication to pushing the boundaries of steel casting development. By embracing advanced materials, cutting-edge technologies, and meticulous quality control, we successfully delivered a solution that enhances efficiency and durability. Our commitment to innovation positions us as a reliable partner for industries seeking top-tier steel casting solutions.

Case Study 2: Enhancing Efficiency and Durability through Advanced Steel Casting Development

We were approached by a leading oil and gas company that required critical components for their offshore drilling equipment. The components had to withstand high pressure, corrosive environments, and extreme temperatures.

Our Solution

After thorough analysis and collaboration with the client, we recommended using a high-strength, corrosion-resistant stainless steel alloy. Our expert team employed advanced casting techniques and precision machining to produce the complex components precisely according to customer specifications.

Results

The components surpassed all quality standards and met the stringent industry requirements. The cast components exhibited exceptional corrosion resistance and durability, ensuring reliable performance in the challenging offshore environments. Our on-time delivery allowed the client to successfully complete their project within schedule, minimizing downtime and increasing operational efficiency.

Case Study 3: Automotive Industry Project Overview

A leading automotive manufacturer required complex engine components with precise dimensions, optimal strength, and superior surface finish for their high-performance vehicles. They faced challenges with their previous castings, including porosity and dimensional inaccuracies.

Our Solution

Working closely with the automotive manufacturer, our engineering team developed an optimized casting process using advanced simulation software. We implemented stricter quality control measures, including advanced dimensional inspection techniques, to eliminate porosity issues and ensure dimensional accuracy.

Results

The new castings exhibited excellent structural integrity, free from any porosity or defects. The precise dimensional accuracy of the components allowed for seamless integration into the automotive engines, enhancing overall performance. The improved surface finish of the castings added to the aesthetic appeal of the vehicles. The decreased scrap rate and increased yield resulted in cost savings for the client.

WHY CALMET?

To maintain a competitive advantage in the steel casting industry, Calmet always evaluates its unique strengths and value proposition. Here are some factors to consider while analyzing competitive advantage that Calmet offers:

Quality and Expertise

Expertise and experience in specialized casting processes, such as investment casting or sand casting, provides an edge over competitors.
Certification of quality standards, adherence to industry-specific regulations, and continuous improvement initiatives has immensely helped Calmet and its customers.

Technological Capabilities

Cutting-edge technology and equipment that Calmet employs significantly enhances the efficiency and quality of the manufacturing process.
Investment in advanced machinery, automation, and digital tools can lead to cost savings, faster production cycles, and better casting outcomes.
Strong R&D capabilities to develop new alloys and casting methods can differentiate a firm from its competitors and attract customers seeking innovative solutions.

Supply Chain Management

Efficient supply chain management, including sourcing raw materials, logistics, and inventory control, can optimize costs and lead times.
Building reliable relationships with suppliers and ensuring a steady supply of high-quality raw materials can give the firm an advantage in meeting customer demands promptly.
Implementing just-in-time manufacturing practices and adopting lean principles can enhance competitiveness by minimizing waste and maximizing efficiency.

Customer Relationships

Developing strong customer relationships and providing exceptional customer service is a way of life at Calmet. Every employee is dedicated to this philosophy.
Understanding customer requirements, providing technical support, and offering customized solutions has helped us stand ahead of competitors.
Regular communication and engagement with customers to gather feedback and address concerns helps in continuous improvement and maintaining a competitive edge.

Cost Efficiency

To remain competitive, controlling costs throughout the manufacturing process is crucial at Calmet.
Implementing cost-effective production strategies, optimizing resource utilization, and managing overhead expenses helps minimize costs.
Continuous evaluation of cost drivers and exploring opportunities to enhance operational efficiency contributes to long-term profitability and competitive advantage.

Sustainable Manufacturing

Sustainable manufacturing focuses on minimizing the environmental impact and maximizing resource efficiency throughout the manufacturing process using the below commonly used techniques:

Energy Efficiency: Implementing energy-efficient measures like optimizing furnace operations, adopting energy-saving technologies, and utilizing renewable energy sources.
Waste Management: Implementing effective waste management techniques, including recycling and reusing materials, reducing waste generation, and implementing proper disposal methods.
Resource Conservation: Employing techniques to reduce water consumption, optimizing raw material usage, and minimizing emissions.
Supply Chain Transparency: Ensuring transparency and responsibility in the supply chain, such as sourcing materials from sustainable suppliers and monitoring the social and environmental impacts of the supply chain.

New Technologies

Innovative technologies can revolutionize the steel casting manufacturing industry, enhancing efficiency, quality, and customization capabilities. Some notable advancements at Calmet include:

3D Printing: The introduction of 3D printing in steel casting allows for complex shapes and design optimization, reducing material waste and lead times while enabling customization.
Automation and Robotics: Integration of automation and robotics streamlines production processes, enhances precision, improves safety, and increases productivity.
Data Analytics and AI: Leveraging data analytics and artificial intelligence can enhance quality control, predictive maintenance, and process optimization, resulting in improved efficiency, reduced costs, and enhanced product quality.
Augmented Reality (AR): AR technology can assist in training, remote maintenance and repair, and real-time quality assurance, improving operational efficiency and reducing downtime.

Industry Regulations

The steel casting manufacturing industry is subject to various regulations, which ensure safety, quality, and environmental compliance. Key regulations may include:

Workplace Safety: Regulations governing occupational health and safety, including maintaining safe working conditions, providing proper protective equipment, and adhering to workforce safety standards.
Environmental Compliance: Regulations related to emissions control, waste management, pollution prevention, and resource conservation to mitigate the environmental impact of operations.
Quality Standards: Compliance with quality certifications such as ISO 9001 ensures that products and processes meet internationally recognized quality standards, fostering customer trust.
Supply Chain Traceability: Regulations and standards may require documentation and traceability of raw materials, ensuring responsible sourcing and avoiding materials with ethical or environmental concerns.

INDUSTRIES

Plumbing

Steel casting utilized for manufacturing plumbing fixtures, valves, and fittings for water supply and drainage systems, providing durable and corrosion-resistant solutions for plumbing installations in residential, commercial, and industrial buildings.