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5 Cs of Investment Casting Foundries in Rajkot Cluster – An Industrial Survey

Sata A. V., Maheta Nikunj R.

Archives of Foundry Engineering

2021

Vol. 21, iss. 3

102--108

Investment casting is very well-known manufacturing process for producing relatively thin and multifarious industrial components with high dimensional tolerances as well as admirable surface finish. Investment casting process is further comprised of sub-processes including pattern making, shell making, dewaxing, shell backing, melting and pouring. These sub-processes are usually followed by heat treatment, finishing as well as testing & measurement of castings. Investment castings are employed in many industrial sectors including aerospace, automobile, bio-medical, chemical, defense, etc. Overall market size of investment castings in world is nearly 12.15 billion USD and growing at a rate of 2.8% every year. India is among the top five investment casting producer in the world, and produces nearly 4% (considering value of castings) of global market. Rajkot (home town of authors) is one of largest clusters of investment casting in India, and has nearly 175 investment casting foundries that is almost 30% of investment casting foundries of India. An industrial survey of nearly 25% of investment casting foundries of Rajkot cluster has been conducted in the year 2019-20 in order to get better insight related to 5 Cs (Capacity; Capability; Competency; Concerns; Challenges) of investment casting foundries located in the cluster. Specific set of questionnaires was design for the survey to address 5 Cs of investment casting foundries of Rajkot cluster, and their inputs were recorded during the in-person survey. The industrial survey yielded in providing better insight related to 5 Cs of foundries in Rajkot cluster. It will also help investment casting producer to identify the capabilities and quality issues as well as leads to benchmarking respective foundry.

Development of Cloud Based Casting Defects Categorization System (CDCS)

Sata A. V.

Archives of Foundry Engineering

2017

Vol. 17, iss. 1

216--222

Defects affect the properties and behavior of the casting during its service life. Since the defects can occur due to different reasons, they must be correctly identified and categorized, to enable applying the appropriate remedial measures. several different approaches for categorizing casting defects have been proposed in technical literature. They mainly rely on physical description, location, and formation of defects. There is a need for a systematic approach for classifying investment casting defects, considering appropriate attributes such as their size, location, identification stage, inspection method, consistency, appearance of defects. A systematic approach for categorization of investment casting defects considering multiple attributes: detection stage, size, shape, appearance, location, consistency and severity of occurrence. Information about the relevant attributes of major defects encountered in investment casting process has been collected from an industrial foundry. This has been implemented in a cloud-based system to make the system freely and widely accessible.