- 2 x Mori Seki NH5000DCG Horizontal machining Center X/Y/Z 730/730/850
- 2 x AEWA BM1100 Vertical machining center X/Y/Z 1100/600/600 with 4 axis
- CNC LER TC- 200B Lathe Dia 10 Length 600
- Microcut CNC Lathe
- 2008 CMM DEA Global Performance 07.10.07
- Microscribe 3 D measuring device
- Universal Lathe X/Y 950/3500
- Universal Lathe TOS2 X/Y 500/2000
- Wotan Boring machine X/Y/Z 800/800/800

2- QUALITY CONTROL

Ersa Foundry utilizes GNR F20 and Spectrolab brand spectrometers to identify the chemical composition of the samples.
Before the casting process starts, from each load and ladle, samples are taken. Depending on the results of the metalurgical analysis done by the machine, after necessary chemical interventions, upon reaching the desired measures, casting process takes starts.
After the comparative chemical analyses of the samples received from the customer and the ones produced in the foundry, the chemical sameness of the samples are strived to reach by the help of the spectrometer. The samples are then forwarded to quality control department for further analysis.
At the furnace we also use Heraus Quick Lab Thermal analysis device to ensure the Carbon equivalence, delta t , (solidification curve)value and Sc (saturated carbon) values.

QUALITY CONTROL DEVICES

- Metallurgical Microscope
- Spectrometer
- Hardness measuring device
- Sample preparation unit
- Fully automated moisture control device (Sensor control)
- Heraus Quick Lab, thermal analız cihazı (Karbon Equivalent)

3- CASTING PROCESS SIMULATION NOTES

Optimal piston velocity profiles, gating designs and overflow positioning can easily be achieved with simulation even for very thin walled
structures. Thermo-mechanical die cycles can be performed to address not only the issue of die life but also in-service part performance, thus reducing manufacturing risks and costs.

High-pressure die casting

LOW PRESSURE DIE CASTING

To reproduce industrial production conditions, mold cycles can be performed numerically until the mold has reached steady state temperature conditions. Based on thermal die profiles, mold filling and solidification results, process parameters can be tuned to achieve optimal process quality while reducing time to market.

Low-pressure die casting

LOST FOAM PROCESS





The simulation of lost foam processes requires a detailed physical modeling of the counter pressure generated by the foam combustion as well as the effect of the permeability of the coating and sand. Simulation provides an accurate solution to the complex physics behind lost foam processes.

Lost foam proccess


POSSIBLE SIMULATION PROBLEMS IN CASTING:



*Metal front progression

*Solidification simulation

*Part deformations

*Metal front progression around a core.

*Metal and air visualization in high pressure die casting

*Porosity prediction




*Shrinkage prediction

Microstructure module:
A deterministic model.

It computes solidification and solid state transformations quantitatively and qualitatively. The evolution of the various phase fractions, as well as their related heat release, is derived from physical microstructure models. Phase compositions such as austenite, ferrite, cementite, graphite, pearlite and martensite can be predicted. It also provides further micro-structural features and material properties such as nodule counts for spheroidal iron and hardness distribution.





* Pearlite distribution in a sand cast spheroidal iron component.