Casting Process

Sand Casting at KDM Groups

At KDM Groups, we are proud to operate one of the most advanced Integrated Special Steel and Alloy Steel Casting facilities. Our plant specializes in producing precision valves and high-quality sand castings for the Oil & Gas, Fertilizer, Chemical, Petrochemical, Power, and Steel industries, as well as Refineries. Here's what sets us apart:

State-of-the-Art Facilities

Our in-house foundry is equipped with a wide range of modern and sophisticated equipment, including continuous moulding lines, heat treatment facilities, shot blasting machines, and large CNC lathes. We also offer comprehensive destructive and non-destructive testing facilities like Spectro, Radiography, Impact, and MPI. This allows us to maintain a high level of quality and precision in all our products.

Environmentally Friendly Operations

Our plant is designed to be both modern and pollution-free. We manufacture valves from carbon steel, stainless steel, and other special alloy castings, ensuring they meet stringent international standards and are suitable for export to global customers.

Quality Assurance

Quality is at the core of everything we do. Our entire manufacturing operation, including the foundry, is governed by strict quality control processes under TQM (Total Quality Management), overseen by experienced QC/QA professionals. Our testing procedures comply with API 600, API 598, API 6A, API 6D, and other relevant ANSI, ASTM, BS, and MSS standards.

Manufacturing Capabilities

Designing & Pattern Making

We use advanced CAD/CAM software to create precise designs and patterns. Our pattern shop is well-equipped to produce wooden, metallic, and shell patterns for a variety of applications.

Melting Shop

Our melting shop houses a battery of medium-frequency induction furnaces with capacities of 3.5 tons, 2 tons, and 1.5 tons for sand castings, and 1 ton and 0.5 ton for shell-molded castings. This flexibility allows us to meet a wide range of manufacturing requirements.

Molding Shop

We have semi-automated and fully automated no-bake molding lines, offering high-quality sand castings with exceptional productivity. Our sand mixer plant has capacities of 80 and 60 tons per hour, respectively. We also operate a sand reclamation plant with a 30-ton per hour capacity, ensuring efficient reuse of materials. Our molding capabilities include shell molding machines and a fully equipped core shop with electric core ovens.

Fettling Shop

The fettling shop features a range of grinders from pencil hand grinders to heavy swing frame grinders, as well as facilities for AC/DC welding with pre-heating arrangements, air arc gouging, and shot blasting. A hydraulic press is available for straightening castings.

Heat Treatment

Our heat treatment facility includes a battery of gas-fired furnaces with capacities up to 7 tons per charge and a maximum operating temperature of 1100°C. The setup ensures precise temperature control, allowing us to meet AMS 2750 standards. Water quenching and polymer quenching are also available.

Quality

With these robust facilities, KDM Groups is your ideal partner for sand casting and precision valve manufacturing. We are committed to delivering exceptional quality, reliable products, and outstanding customer service.