Peekay

Industrial Training
at
Peekay Steel Casting Pvt. Ltd.

Report
Submitted to : Dr. K.R. Guruprased Submitted by: Anjoom Moopan
16ME217
Contents
I. Industrial Training Certificate

1. Introduction
2. Patterns
3. Molding
4. Melting
5. Fettling
6. Machine shop
7. Quality Assurance
7.1. Lab
7.1.1. Spectrolab
7.1.2. Mechanical Testing
7.2 Heat Treatment
8. Quality Control
8.1 Visual method
8.2 Magnetic Particle Inspection (MPI)
8.3 Dipenetrant Test (DI)
8.4 Radiographic Test (RT)
8.5 Ultrasonic Test (UT)
9. Process Flowchart
10. Conclusion
1. Introduction
Peekay Steel Castings Pvt. Ltd. Is one of the largest steel foundries in Asia. They produce single
piece castings of sizes up to 15 tons. They manufacture products like valve components like
control, plug and butterfly valves.
The industrial training at Peekay Steels was scheduled for a month from June 5 to July 5. Being
one of the largest foundries, Peekay Steels provided an amble opportunity for me to study the
various processes and techniques involved in sand casting of steel.
The objective of the industrial training was to provide the students with an opportunity to walk
around the various departments in the steel plant and observe the different processes going on,
and thus to get a first-hand experience on sand casting of steels.
2. Patterns
The manufacturing process at Peekay Steels starts with the feasibility study of the product design
from the customer. If the design is feasible, it is forwaded to the Patterns department. Pattern
making is outsourced, and plywood is used to make the patterns. Once the pattern I brought in,
thhe dimensions are checked against the tolerance range. Later, the positions for in-gate, out-gate
and chills are marked on the pattern. Once this is done, it is sent to the molding department.
3. Molding
The pattern is brought to the molding shop for mold preparation. This is done in two sections,
namely, Heavy Steel Foundry (HSF) and Light Steel Foundry (LSF). As the name suggests, it is
based on the size of the cast.
The molding sand consists of industrial silica sand, black sand, additives like resin, slow
hardener, fast hardener, and reclaimed sand. The pattern is placed inside cope or drag and is
filled with molding sand with IMF mixer. Timely interventions are done to place the chills and
gate bricks. Once enough sand filled it is rammed and set aside for hardening. The prepared mold
is then passed on to the melting department.
Molding shop has a thermal reclamation unit. After every casting is prepared, the sand is
reclaimed for further use. This is done with the help a refrigeration unit that cools the sand,
which is around 200oC, to 55oC. The reclaimed sand is used along with fresh sand. Using a
proportion of reclaimed sand increases the strength of the mold.
4. Melting
Raw material used for melting is scrap steel, which are crushed into a cube shape.
Electromagnets are used to pick up the steel and drop them into the furnace. Furnace is fueled by
LPG. Workers are required to wear apron, masks and goggles, in addition to safety shoes and
helmet, due to the hazardous nature of the furnace.
Small scale liquid metal eruptions occur in the furnace due to the presence of alkali. By
equipping advanced methods to select only steel from the scrap can help in better safety of the
employees.
Once the steel is melt, it is poured into a huge ladle, supported by an overhead crane. Each
pouring is called a heat. From each heat a small casting is made to check its chemical
composition. Then the melt metal is poured into the mold. The mold is then kept aside for 2 to 5
days for solidification of metal.
Solidification is followed by shake-out process. Casting is taken out from the mold and then the
mold is shaken well to loosen the sand, which is send back to thermal reclamation unit. The
casting is undergone gas-cutting to remove riser, gates, runners and sprue. It is then sent to
fettling shop.
5. Fettling
Castings are undergone grinding to achieve surface finish. Then they are undergone Non-
Destructive Test (NDT) methods to locate flaws and cracks. NDT methods are discussed in
detail in Quality Control.
Parts where cracks are found are gouged to open it up. When electrode touches the casting, metal
melts and high pressure air is passed so that metal comes out. Later welding is done with a steel
filler to close the opening. TIG and Arc welding methods are equipped. NDT is done again to
detect flaws. Finally, shot-blasting, a method in which small granules are made to hit the surface
of the cast with high pressure, is done for better finish. The product is then sent to machine shop.
6. Machine Shop
Machine shop has various metal removing machines including:
i. Conventional Vertical Turret Lathe

ii. CNC Vertical Turret Lathe
iii. Horizontal Boring and Milling machine
iv. Radial drilling machine
After the required machining processes are done, NDT methods are done again. For valve
components, hydrotesting is done, which is a method where components are assembled and
demineralized water is passed through them at a high pressure to check for any leakage.
Once all the tests are done and satisfied, the product is covered with plastic covers and is packed
in wooden crates for shipping.
7. Quality Assurance
7.1. Lab
7.1.1. Spectrolab
Spectrolab tests the chemical composition of steel for every heat from melting shop. It is a
completely computerized testing process and every result is registered on a digital log.
7.1.2. Mechanical Testing
Conventional mechanical testing methods are done on sample products from heat to ensure the
strength of the castings. The tests include impact, hardness and tension tests.
7.2 Heat Treatment

Different heat treatments are done on the casted product to meet the client requirements. Heat
treatment has three different stages: heating, soaking, and cooling. As per the client’s instructions
water quenching, air cooling, or furnace cooling is done.
Soaking
Temperature
Heating
Cooling
Time
8. Quality Control
Quality control mainly consists of Non-Destructive Tests (NDT). The products casted are very
expensive and large, so destructive testing methods cannot be employed. The five NDT methods
employed are:
8.1 Visual method

It is simply a visual way of finding flaws on the surface. Such flaws are marked and sent for
grinding.
8.2 Magnetic Particle Inspection (MPI)

The casting is washed with water mixed with magnetic particles. A magnetic probe is then used
to magnetise the casting, where the magnetic particles form non uniform patterns over regions
with internal cracks.
8.3 Dipenetrant Test (DI)

It is a test based on capillary action. Penetrant, a spirit based red coloured liquid, is poured all
over the surface, where it gets absorbed into cracks. Casting is then washed. Later white colored
liquid is applied over the casting, so that the penetrant in the cracks are visible as red spots.
Flawed products are sent back for corrections.
8.4 Radiographic Test (RT)

X-ray of the cast is taken to look for any cracks. This method is aimed at showing internal
cracks.
8.5 Ultrasonic Test (UT)

Ultrasonic Test is also a test to find internal cracks. An ultrasonic instrument is used on the
surfaces of the casting. The instrument gives a graphical representation of both extreme ends.
Internal cracks, if present are shown as abnormal peaks in the graph.
9. Process Flowchart
Pattern Molding Melting Shakeout Gas cutting
Heat treatment NDT Fettling Heat treatment
Machine shop Dispatch
10. Conclusion
Steel casting process is a very long and slow process. Producing casts based on customer
requirements and designs, and not bulk production makes it even more long as automation
cannot be done. Ultimately, quality of the castings is the most crucial part in the business, so a
lot of care has to be given for the entire process.
Peekay Steels, being one of the largest foundries, provided me the best opportunity to learn about
the casting processes and techniques followed in real industries, which is otherwise taught within
classrooms. So I could take out the classroom lessons about sand casting of steel and view it in a
real life experience.
The industrial training done in Peekay steels would be an asset in my career as an engineer.

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Industrial Training

Peekay Steel Casting Pvt. Ltd.

Submitted to : Dr. K.R. Guruprased Submitted by: Anjoom Moopan

I. Industrial Training Certificate

i. Conventional Vertical Turret Lathe

7.2 Heat Treatment

8.1 Visual method

8.2 Magnetic Particle Inspection (MPI)

8.3 Dipenetrant Test (DI)

8.4 Radiographic Test (RT)

8.5 Ultrasonic Test (UT)

Pattern Molding Melting Shakeout Gas cutting

Heat treatment NDT Fettling Heat treatment

Machine shop Dispatch

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