Casting is a 6000 year old manufacturing process. Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.
Aluminium casting processes are classified as Ingot casting or Mould casting. During the first process, primary or secondary aluminium is cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot which are subsequently transformed in semi- and finished products.
The second process is used in the foundries for producing cast products. This is the oldest and simplest (in theory but not in practice) means of manufacturing shaped components.
Manufacturing process
A high quality Alloy Ingot is the result of a well set system and process. It has been our endeavor to improve the quality of the ingots we manufacture and to achieve this, the below process has been adopted & implemented.
Quality management
All input raw materials are off loaded and kept separately quality wise and are then meticulously sorted and cleaned before being sent for melting.
Raw materials, In-process materials & finished products are tested as per Quality plans.
Samples are drawn before and after the Ingots are cast to maintain Homogeneity in the material.
Assessment on identification of each batch / heat is done and separate color codes and heat numbers are mentioned.
Specific requirements / advices of customers are taken into account from time to time to enable us to serve them better.
Quality Aluminium Alloys
At Almet, we follow strict quality standards in all areas of operations. Our plant is well equipped with the most advanced analysing instruments. Every heat is checked intensely for its chemical composition, grain structure, dross & sludge content, gas cavities and its physical strength. Samples are checked at various stages to ensure the uniformity of the melt
At Almet, we maintain high quality of standards for our products and services. A list of lab equipment is given below
Optical Emission Spectrometer
Porosity testing machine
Sample polishing machine
Shipment Process for Aluminium Ingots
Marking – Colouring coding & numbering is done for every heat to differentiate alloys
Bundling & Strapping – Ingots are stacked in bundles weighing approx 500 Kgs. and are strapped with PVC/MS strip as per customer requirement and are further packed with stretch film so as to avoid oxidization on the ingots
Packing list & Test Certificate – All heats are supplied with a test certificate & packing list and every bundle is tagged for its weight, number of pieces, alloy & colour code.
Loading – Bundles are properly stacked into trucks or containers with the help of fork lift & crane so as to ease the off loading at the customers place.
