Foundry - PNP Corporation

Our foundry is consistent in yielding the best results, with the strong support of updated technology, ever-growing infrastructure, constantly rising productivity and unmatched Quality.

Air Cooled Blocks

We manufacture Air Cooled Blocks and casting of these block is done in grey cast iron of Grade-25 In such a way so as to achieve pearlite structure free from ferrite and graphite (max up to 2-3%). Air cooled block are cast by shell molding process and used for diesel engines, automobile engines (two wheeler, three wheeler engines, all European engines and high power diesel engines).

Applications:

Diesel engines
Automobile engines
European engines
High power diesel engines
All types of Air Compressors

Material	Grey cast iron
Cooling Method	Air Cooled
Head Shape	Round
Surface Finished	Polished
Application	Automobile
Material Grade	Grade-25

Metal Testing Lab Instruments

Spectrometer

Metal Power Spectrometer used to verify the constituents of every metal melt before it is poured to ensure that it meets BSI standards.

Hardness Testing Machine

Brinell hardness is determined by forcing a hardened steel or carbide ball of known diameter under a known load into a surface and measuring the diameter of the indentation with a microscope.

CE Meter

Equivalent carbon content (CE) concept is used to understand how alloying elements will affect the heat treatment and casting behavior.

Sand Testing Lab Instruments

Hot tensile Strength (HTS) tester

Peelback tester

Sieve shaker

Hot tensile Strength (HTS) tester

Peelback tester

Sieve shaker

Core gas determinator

Core Hardness tester

Plant Machinery

Shell Dump Box

Core Shooter

Shot Blasting Machine

We manufacture all types of shell molding castings (CI and SG iron). Shell molding foundry caters to those who require good surface finish like air cool blocks used in auto sector, various compressor parts, various parts of pumps and valves, cylinder heads, etc. Shell molding foundry uses resin coated sand as the most crucial raw material which will be used to prepare molds and cores of the castings for excellent surface finish. We have in-house facility to produce resin coated sand. We possess the manufacturing capacity of producing 100 Mt per month.

The 6-Step Process of Shell Mold Casting

#1) Creating the Pattern

Creating the pattern is the first step in shell mold casting. Usually, the patterns used in this molding process consist of two pieces of metal in a custom form as desired for the finished casting, such as iron or steel.

#2) Creating the Mold

A mold is formed after the pattern has been made. Both of the pattern components are heated during this stage and then treated with a lubricant. The sections of the pattern are then placed into a large container that holds the resin-covered sand, known as a dump box. Once inserted into the dump box, the pattern parts themselves will become covered in the sand.

#3) Assembly of Pattern Parts

Now it’s time to assemble the pattern parts. The top and bottom pieces of the pattern are joined together during this stage. It can feature a locking mechanism that keeps the two parts together, depending on the type of pattern. They are then put into a flask until completely secured. Here, after the model parts have been assembled, they will be exposed to molten metal, which is the procedural stage.

#4) Exposure to Molten Metal

In the shell mold casting process, the fourth stage pours molten metal into the cavity of the mold. In this molding process, different types of metals and alloys may be used, including steel and iron. Regardless, the metal or alloy is heated until it turns to a liquid state, after which the molten metal is poured into the mold’s cavity to form of a hardened shell.

#5) Wait to Cool

Before forming a hardened shell and, thus, the casting, the molten metal must cool. Usually, at room temperature, the pattern parts are allowed to cool. The molten metal will harden to create a shell as the model parts cool.

#6) Ejecting the Casting

The sixth and final step in the shell mold casting process is ejecting the casting from the mold’s cavity. Since a two-piece pattern is used in this casting process, castings are easily ejected by “opening” the pattern. The top and bottom pattern pieces are isolated from each other, at which stage it is possible to safely eject the newly formed casting.

Advantages of Shell Casting

A variety of significant benefits are offered by Shell casting.

It permits the creation of very complex, detailed metal components. It provides an excellent way for small and medium-sized shapes to be made, especially parts requiring precise production.
This type of casting today can occur in highly automated environments; after the development of the metal pattern, processing does not impose a high demand for labor.
Since shell casting generates intricate parts repetitively, manufacturers utilizing this process may avoid some manufacturing tooling costs required for other production processes. Fourth, shell casting can result in the development of very attractive exterior surfaces, depending on the raw materials used. Parts may require a minimal investment in finishing, for instance.
Shell casting utilizes raw materials with a high degree of efficiency. Usually, manufacturers that use this approach can save metals and metal alloys without wasting these properties. As with many other types of casting, a manufacturer may simply re-melt it and reuse the constituent raw materials when a work piece fails to meet the necessary requirements.
Since this casting process is ideal for automation in high volume manufacturing environments, it enables businesses to rapidly produce large quantities of metal parts. The manufacturing of expendable shell molds can occur repeatedly. While a manufacturer will eventually need to replace the metal pattern, that cost arises infrequently.