PSG FOUNDRY

Layout, Infrastructure and Melting practices

SREEKAANTH P
23MY02
Introduction

PSG Foundry, part of the PSG & Sons Charities is a

leading foundry known for its precision engineering and
high-quality casting solutions. Established in 1975, the
foundry serves various sectors including automotive,
agriculture, and general engineering.
Foundry layout
Foundry Layout
The PSG Foundry is designed to facilitate efficient workflow and
optimal productivity. The layout is divided into several key
sections:

1.Raw Material Storage: Strategically located near the melting

units to minimize transportation time.
2.Melting Section: Houses the induction and cupola furnaces,
central to the foundry’s operations.
3.Moulding Area: Includes automatic and semi-automatic
moulding lines, positioned adjacent to the melting section.
4. Core Making Area: Equipped with shell core, cold box, and
no-bake core processes, located near the moulding area.
5. Casting and Cooling: Cast parts are allowed to cool before
moving to the finishing section.
6. Finishing and Inspection: Areas for shot blasting, grinding,
machining, and quality inspection.
7. Storage and Dispatch: Finished products are stored before
being dispatched to customers.
Infrastructure
PSG Foundry’s infrastructure supports high-quality and efficient production. Key
components include:

1.Melting Units:
• Induction Furnaces: Medium frequency coreless induction furnaces with capacities
ranging from 500 kg to 3 tons.
• Cupola Furnaces: Continuous operation cupola furnaces suitable for high-volume
production.
2.Moulding Lines:
• Automatic Moulding Lines: High-speed, high-precision moulding lines for large
production runs.
• Semi-Automatic Moulding Lines: Flexible and cost-effective for smaller batches
and varied casting sizes.
3. Core Making Facilities:
• Shell Core Process: For high precision and complex core shapes.
• Cold Box Process: Efficient for high volume and strength.
• No-Bake Process: Ideal for large, heavy-sectioned castings.
4.Finishing Equipment:
• Shot Blasting Machines: For cleaning and surface preparation.
• Grinding and Fettling Equipment: For removing excess material and finishing
the castings.
• CNC Machining Centers: For precision machining of cast parts.
5.Quality Control Laboratories:
• Spectrometric Analysis: Ensures accurate chemical composition.
• Thermal Analysis: Monitors cooling and solidification behavior.
• Metallographic Examination: Verifies microstructure and quality.
6. Environmental and Safety Systems:
• Fume Extraction: Advanced systems to capture and neutralize
emissions.
• Waste Management: Programs for recycling slag and other by-
products.
• Safety Protocols: Comprehensive safety measures for worker
protection.
Melting Practices

Induction Furnaces
➢Technology: Coreless induction furnaces provide precise temperature
control.
➢Capacity: Ranges from 500 kg to 3 tons.
➢Material Handling: Uses high-grade raw materials such as pig iron, scrap
steel, and ferroalloys.
➢Efficiency: Energy-efficient with rapid melting capabilities.
Cupola Furnaces

❖Operation: PSG Foundry also operates cupola furnaces for melting iron.
These furnaces are capable of continuous operation and are suitable for
high-volume production.

❖Charge Material: The charge typically consists of pig iron, foundry

returns, steel scrap, and coke. The charge is carefully calculated and
layered to ensure optimal melting.

❖Efficiency: Cupola furnaces are known for their high melting rates and
cost-effectiveness in large-scale production environments.
Melt Treatment Processes

1.Inoculation: Adds inoculants to refine grain structure and enhance mechanical properties.
2.Nodulization: Adds magnesium or magnesium alloys for ductile iron, forming nodular graphite
structures.
3.Deslagging: Removes impurities and non-metallic inclusions, ensuring clean molten metal.

Quality Control in Melting

1.Spectrometric Analysis: Continuous monitoring of chemical composition.

2.Thermal Analysis: Assesses cooling characteristics and solidification.
3.Metallographic Examination: Examines microstructure to confirm quality and defect-free
metal.
Environmental and Safety Measures

1.Fume Extraction: Systems in place to capture harmful emissions.

2.Waste Management: Recycling programs to minimize waste.

3.Worker Safety: Protocols and PPE to protect against high-temperature hazards.

Conclusion
PSG Foundry’s layout and infrastructure are meticulously designed to ensure efficient
production and high-quality outputs. Their melting practices blend traditional methods
with advanced technology, emphasizing quality control and environmental sustainability.
This comprehensive approach positions PSG Foundry as a leader in the casting industry.
 Aqua Sub
Layout, Infrastructure and Melting practices
Introduction

Aqua Sub Engineering, located in Coimbatore, is a prominent

foundry known for its high-quality casting solutions, primarily
serving the pump and motor manufacturing industries.
Established with a focus on innovation and quality, the foundry is
equipped with state-of-the-art infrastructure and follows best
practices in melting and casting.
Foundry Layout
The layout of Aqua Sub Engineering Foundry is designed to optimize
workflow efficiency and ensure high-quality production. The facility is divided
into several key areas:

1.Raw Material Storage: Located close to the melting units to streamline

material handling and reduce transportation time.
2.Melting Section: Equipped with both induction and cupola furnaces,
centrally located to serve the moulding areas effectively.
3. Moulding Area: Comprises automated and manual moulding lines,
situated adjacent to the melting section for seamless material flow.
4.Core Making Area: Houses various core making processes like shell
core, cold box, and no-bake, positioned near the moulding section.
5.Casting and Cooling: Designated areas for casting and controlled cooling
of the molten metal.
6. Finishing and Machining: Areas for shot blasting, grinding, and
machining to finish the castings.
7.Quality Control and Inspection: Laboratories and inspection areas to
ensure the quality of the final products.
8.Storage and Dispatch: Storage space for finished products before they
are dispatched to customers.
Infrastructure
• Aqua Sub Engineering Foundry boasts advanced infrastructure to support its high-quality
casting operations. Key components include:

1.Melting Units:
• Induction Furnaces: High-efficiency induction furnaces with capacities ranging from
500 kg to 2 tons.
• Cupola Furnaces: Traditional cupola furnaces for large-scale melting operations,
capable of continuous production.
2.Moulding Lines:
• Automatic Moulding Lines: High-speed, precision moulding lines for large
production runs.
• Manual Moulding Lines: Flexible moulding setups for smaller batches and custom
orders.
3. Core Making Facilities:
• Shell Core Process: Produces high-precision cores for intricate
castings.
• Cold Box Process: Offers high productivity and core strength.
• No-Bake Process: Suitable for large and heavy-sectioned castings.
4.Finishing Equipment:
• Shot Blasting Machines: For surface cleaning and preparation.
• Grinding and Fettling Equipment: For removing excess material and
finishing the castings.
• CNC Machining Centers: For precision machining and finishing of
cast components.
5. Quality Control Laboratories:
• Spectrometric Analysis: Ensures accurate chemical composition of the metal.
• Thermal Analysis: Monitors cooling and solidification behavior.
• Metallographic Examination: Verifies microstructure and ensures the absence of
defects.
6.Environmental and Safety Systems:
• Fume Extraction: Advanced systems to capture and neutralize harmful emissions.
• Waste Management: Efficient recycling programs for slag and other by-products.
• Safety Protocols: Comprehensive safety measures to protect workers from the
hazards associated with foundry operations.
Melting practices
Induction Furnaces

• Technology: Coreless induction furnaces provide precise temperature

control, ensuring consistent quality.
• Capacity: Ranges from 500 kg to 2 tons, suitable for various batch sizes.
• Material Handling: Uses high-quality raw materials like pig iron, steel
scrap, and ferroalloys.
• Efficiency: Energy-efficient and capable of rapid melting, reducing
production time.
Cupola Furnaces

• Operation: Ideal for continuous, high-volume production with significant melting capacity.
• Charge Material: Includes pig iron, foundry returns, steel scrap, and coke for efficient
melting.
• Cost-effectiveness: High melting rate makes it cost-effective for large-scale operations.

Melt Treatment Processes

1.Inoculation: Addition of inoculants to the molten metal to refine grain structure and enhance
mechanical properties.
2.Nodulization: For ductile iron, magnesium or its alloys are added to create nodular graphite
structures, improving strength and ductility.
3.Deslagging: Regular removal of slag and impurities to ensure clean and homogeneous
metal.
Quality Control in Melting

1. Spectrometric Analysis: Continuous monitoring of the metal's chemical composition to meet

specifications.
2. Thermal Analysis: Evaluates cooling characteristics and solidification patterns.
3. Metallographic Examination: Ensures the desired microstructure and absence of defects in the
metal.

Environmental and Safety Measures

1. Fume Extraction: Systems in place to capture and neutralize emissions from the melting
processes.
2. Waste Management: Effective recycling programs to minimize waste and environmental impact.
3. Worker Safety: Rigorous safety protocols and the use of personal protective equipment (PPE) to
ensure worker safety.
Conclusion
Aqua Sub Engineering Foundry's well-planned layout and advanced
infrastructure support efficient and high-quality casting production. Their
melting practices, combining traditional methods with modern technology,
emphasize quality control, environmental sustainability, and worker safety.
This comprehensive approach ensures the foundry's position as a leader in
the industry.