Our pattern shop produces wooden or resin patterns from your drawing, OEM sample or part number. Moulds are designed with the correct shrinkage allowance, draft angle and feeding system for the part.

Why it matters: Shrinkage allowance and feeding design decide whether a casting comes out dimensionally correct and internally sound. A pattern that is right for one alloy is often wrong for another, so the pattern is matched to the material being poured.

Quality control: Dimensional check and 3D verification of the pattern before release to production.

Przychodzący złom stalowy, pig iron and ferro-alloys are inspected for chemistry and cleanliness. Approved material is released to the melting shop with an internal batch number.

Why it matters: No heat treatment or machining step can correct bad chemistry. Contaminated or mis-sorted scrap is the single most common cause of an out-of-spec manganese heat, so material is verified before it reaches the furnace.

Quality control: Spectrometer analysis of incoming alloy material; visual cleanliness check on scrap.

Melting is carried out in medium-frequency induction furnaces sized from 1.25 t to 5 t depending on casting weight and batch size. Final chemistry and temperature are adjusted in the ladle.

Why it matters: Carbon and manganese content determine whether the austenitic structure will be stable after heat treatment. Pouring temperature decides how well the mould fills and how much shrinkage porosity ends up in the finished part.

Quality control: A spectrometer sample is taken from every heat and the result recorded before pouring is authorised.

Moulds are produced by lost-foam (EPC), V-process vacuum moulding or sand casting depending on the part geometry and quantity required. Cores for internal cavities are made and assembled.

Why it matters: Mould hardness, coating and core positioning control surface finish, dimensional accuracy and which defects a casting will tend to develop. The process route is selected per part rather than applied uniformly.

Quality control: Visual and dimensional inspection of the assembled mould, plus core position check, before pouring.

Molten steel is poured into the moulds at a controlled temperature and pouring rate. Risers and gating systems feed the casting as it solidifies.

Why it matters: Pouring too cold produces misruns and cold shuts; pouring too fast erodes the mould. Feeding design determines whether the last section to solidify receives liquid metal or ends up with shrinkage voids.

Quality control: Pouring temperature and time are logged for every casting, and traceable to the heat number.

Castings cool in the mould for the prescribed time, then the moulding sand is removed. Risers and gating systems are cut off and the raw casting is cleaned.

Why it matters: Cooling too quickly in the mould creates internal stress that can cause cracking during heat treatment or in service. The cooling time is set by section thickness rather than by production convenience.

Quality control: Visual inspection of the raw casting for surface defects; section thickness check on critical areas.

Solution treatment and water toughening for manganese steel; quenching and tempering for high chrome alloy and alloy steel. Furnace size is matched to the casting so that it heats evenly.

Why it matters: This is the step that creates the material properties. For high manganese steel it dissolves carbides back into the austenite so the part work-hardens in service instead of failing early; for high chrome iron it develops the martensitic matrix and carbide structure that give the hardness.

Quality control: Furnace records are kept per batch, and hardness is tested after heat treatment before the part moves to machining.

Castings are brought to OEM dimensions by CNC and conventional machining, including turning, milling, drilling and tapping. Large vertical lathes and hydraulic straightening presses handle oversize parts and distortion correction.

Why it matters: Wear parts are fitted onto existing crushers and mills, so mounting faces, bolt holes and locating shoulders have to match the original geometry. Dimensional error here shows up as premature bolt failure or uneven wear in service.

Quality control: Dimensional inspection against the customer drawing, using calibrated gauges and templates for every critical dimension.

Final inspection is completed and the documentation package is compiled. Parts are packed in steel-framed wooden cases lined with waterproof film, with shipping marks per customer requirements.

Why it matters: The documentation package is what allows a plant to accept the parts into stores and to trace them later. Packing determines whether heavy castings arrive undamaged — and whether the mounting surfaces still meet tolerance after a long ocean voyage.

Quality control: Final inspection before packing, with a photo record and a complete document set for the shipment.