Description
INTRODUCTION
COMPOSITION OF DUCTILE IRON CASTINGS
DUCTILE IRON
COMPOSITION
COMMON DUCTILE IRON GRADES
THE FAMILY OF DUCTILE IRON
PROPERTIES OF DUCTILE IRONS
BENEFITS OF DUCTILE IRON
USES AND APPLICATION
APPLICATIONS
DUCTILE IRON APPLICATION
1. PRESSURE PIPES AND FITTINGS
2. AUTOMOTIVE APPLICATIONS
3. AGRICULTURE, ROAD AND CONSTRUCTION APPLICATIONS
4. GENERAL ENGINEERING APPLICATIONS
B.I.S. SPECIFICATION
PROCESS FLOW CHART
PRODUCTION PROCESS
(1) RAW MATERIAL
CHEMICAL COMPOSITION OF THE BASE IRON
A. TOTAL CARBON
B. MANGANESE
C. PHOSPHORUS
D. SULPHUR
E. SILICON
F. NICKEL
G. OTHER ELEMENTS
PHYSICAL CONDITION OF THE BASE IRON
CHARGE MATERIALS
A. PIG IRON
B. STEEL SCRAP
C.S.G. IRON RETURNS
D. OTHER CHARGE MATERIALS
(2). MELTING AND COMPOSITION CONTROL
MELTING UNITS
A. CUPOLAS
B. AIR FURNACES
C. INDUCTION MELTIUG FURNACES
D. ELECTRIC ARC FURNACES
CONTROL OF MELT
A. DESULPHURIZATION OF THE MELT
B. NODULISATION OR SPHERIODATION (MAGNESIUM TREATMENT)
TREATMENT ALLOYS
A. MAGNESIUM MASTER ALLOYS
CHOICE OF MASTER ALLOYS
POURING TEMPERATURES FOR CASTINGS
SPHEROIDIZATION TECHNIQUES
CLASSIFICATION OF PROCESSES
I) PROCESSES WHICH USE MG MASTER ALLOYS
A) LADLE TRANSFER PROCESSES,
A) LADLE TRANSFER PROCESSES
I) OPEN LADLE PROCESS
II) SANDWICH PROCESS
III) PUDDING PROCESS
IV) TRIGGER PROMS
B) PROCESSES OTHER THAN LADLE TRANSFER
I) PLUNGING PROCESS
II) POROUS PLUG PRACTICE
III) INSMOULD PROCESS
IV) T-KNOCK PROCESS
V) FLOTRET PROCESS
B) PROCESSES WHICH USE PURE MAGNESIUM
I) PRESSURE LADLE AND PRESSURE CHAMBER TECHNIQUES
II) INJECTION PROCESS
III) G.F. CONVERTOR PROCESS
IV) DETACHABLE BOTTOM LADLE PROCESS
INOCULATION
EFFECT OF INOCULATION
(3) CASTING
SAND CASTING
ADVANTAGES OF SAND CASTING
DISADVANTAGES OF SAND CASTING
(A) PATTERNMAKING
(B) CORE MAKING
(C) MOLDING
(D) CLAMPING
(E) MELTING & POURING
(F) COOLING
(G) REMOVAL
(H) TRIMMING
(I) CLEANING
(J) QUALITY CONTROL
CASTING DEFECTS
DEFECTS RELATED WITH SAND MOLDS 61
INSPECTION METHODS
(4) HEAT TREATMENT
I) STRESS RELIEF
II) SUB-CRITICAL ANNEALING
III) FULL ANNEALING
IV) NORMALIZING
V) QUENCHING AND TEMPERING
(5) QUALITY CONTROL (INSPECTION AND TESTING)
INSPECTION METHODS
INSPECTION METHODS TO DUCTILE IRON CASTINGS
1. VISUAL INSPECTION
2. MAGNETIC PARTICLE (POWDER) INSPECTION
3. ULTRASONIC TESTING
A. TENSILE TEST
B. IMPACT TEST
C. HARDNESS TEST
MARKING
FURNACE USED FOR MELTING
(A) COUPLA FURNACE
COLD BLAST CUPOLA OPERATION
METALLIC CHARGE MATERIALS
HARMFUL MATERIALS
SIZE OF METALLIC CHARGE MATERIALS
FERROALLOYS
CUPOLA OUTPUT
EMISSIONS FROM CUPOLAS
HOT BLAST CUPOLA
CONSTRUCTION OF COUPLA FURNACE
STRUCTURE OF CUPOLA FURNACE
AS SEEN FROM THE FIG, THE MAIN PARTS OF CUPOLA ARE
(I) SHELL
(II) FOUNDATION
(III) CHARGING DOOR
(IV) CHARGING PLATFORM
(V) AIR BLOWER
(VI) TUYERES
(VII) VOLUME METER
(VIII) TAP HOLE (MOLTEN METAL HOLE)
(IX) SLAG HOLE
(X) CHIMNEY
OPERATION OF CUPOLA FURNACE
THE OPERATION OF CUPOLA FURNACE CONSISTS OF FOLLOWING STEPS
(I) PREPARATION OF CUPOLA
(II) FIRING OF CUPOLA
(III) CHARGING THE CUPOLA
(IV) SOAKING OF IRON
(V) STARTING THE AIR BLAST
(VI) CLOSING THE CUPOLA
ZONES OF CUPOLA FURNACE
THE FOLLOWING ARE THE SIX IMPORTANT ZONES
(I) WELL OR CRUCIBLE ZONE
(II) COMBINATION ZONE
(III) REDUCING ZONE
(IV) MELTING ZONE
(V) PREHEATING ZONE
(VI) STACK ZONE
CAPACITY OF CUPOLA FURNACE
ADVANTAGES OF CUPOLA FURNACE
LIMITATIONS OF CUPOLA FURNACE
(B) INDUCTION FURNACE
THE CHANNEL FURNACE
THE CORELESS INDUCTION FURNACE
CHARGE MATERIALS
SLAG REMOVAL
REFRACTORIES FOR CORELESS INDUCTION FURNACES
OPERATING SYSTEMS
FUME EXTRACTION
IRON MAKING IN INDUCTION FURNACE
RAW MATERIALS
CHARGE PREPARATION AND CHARGING
MELTING AND SLAG REMOVAL
MAKING THE HEAT READY, TAPPING AND EMPTYING THE FURNACE
PROCESS CONTROL AND AUTOMATION
PROCESS AUTOMATION
PROCESS MONITORING
INFORMATION DISPLAY AND RECORDING
INTERFACING WITH OTHER FURNACES AND CONTROL SYSTEMS
MARKET OVERVIEW
NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION
EXPORT POSSIBILITY
INDIAN FOUNDRY INDUSTRY9
GENERAL ECONOMIC SCENARIO
FORECASTS OF GROWTH BY LEADING INSTITUTIONS
MAJOR FOUNDRY CLUSTERS
TOTAL PRODUCTION OF TRACTORS IN INDIA
GLOBAL SCENARIO
ROLE IN MANUFACTURING SECTOR
PRODUCTION IN MILLION TONS
EXPORTS IMPORT TRENDS
SECTORWISE CONSUMPTION OF CASTING
INDIAN FOUNDRY INDUSTRY EXPECTS US 3 BN INVESTMENT
THE BRIGHT FUTURE OF CASTING IN INDIA
1. THE ‘MAKE IN INDIA’ CAMPAIGN
2. FOCUSING ON STRUCTURAL CHANGE SINCE 2015
3. THE BOOMING GROWTH OF THE AUTO INDUSTRY
4. MISCELLANEOUS OPPORTUNITIES
CASTECH FOUNDRIES
OBJECTIVES OF THE STUDY
TARGET AUDIENCE
SCOPE OF THE REPORT
MANUFACTURERS/SUPPLIERS OF DUCTILE IRON CASTING
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PIG IRON
SUPPLIERS OF CAST IRON SCRAP
SUPPLIERS OF STEEL SCRAPE
SUPPLIERS OF SILICON CARBIDE
SUPPLIERS OF FERRO SILICON
SUPPLIERS OF MAGNESIUM INGOT
SUPPLIERS OF FERRO MANGANESE
SUPPLIERS OF FIRE CLAY
SUPPLIERS OF BENTONITE
SUPPLLIRS OF COAL DUST
SUPPLIERS OF GRAPHITE POWDER
SUPPLIERS OF SILICA SAND
SUPPLIERS OF LIME STONE
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF HEATREATMENT FURNACE
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF ALUMINIUM PATTERNS
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
SUPPLIERS OF SAND SIEVING MACHINE
SUPPLIERS OF SQUEEZE MOLDING MACHINE
SUPPLIERS OF SHAKEOUT MACHINE
SUPPLIERS OF CORE SHOOTER MACHINE
SUPPLIERS OF DRYING OVEN
SUPPLIERS OF FOUNDRY TOOLS
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
PLANT LAYOUT
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)