- We have 1x150 kg, 1x250kg, 1x350 kg double crucible induction furnace and 250 tons/month of active melting capacity of steel, stainless steel, aluminum, bronze.
- Complex parts are cast from 0.5 gr - 105 kg steel and 10 gr - 50 kg aluminum material.
- Normalization and Stress Relief for steel materials, Solution and Aging heat treatment for aluminum alloys are carried out in our own facility.
Mold Design and Production:
In order to provide the best casting parameters for the requested product, Unimetal uses the latest CAD technologies to supply the wax injection mold to its customers with competitively advantageous costs. Fixtures that provide and support the dimensional consistency of the wax injection mold are designed in-house according to the technical drawing dimensions of the part in order to repeat the measurement precision.
Candle Model Production:
Wax model production is the first step in the investment casting process. The surface quality of the wax model directly affects the surface quality of the part. Horizontal and vertical injection presses are used for this process, which consists of injecting the molten wax into a metal mold. PLC system is integrated to our injection presses in our company and high efficiency is ensured by recording the relevant production parameters for the injection process.
Candle Mounting:
The next step in the production of parts with investment casting is to create product clusters from wax models. At the next stage after injection, wax models are mounted on runners and heads to form clusters. Assembly Process Plans created for each part are used in the formation of the cluster. Thus, the assembly parameters are fixed and continuity in quality is ensured.
Ceramic coating:
Ceramic operation is one of the most critical steps for investment casting technique. The wax cluster is covered with ceramic mud baths and refractory material. Coating materials and thickness vary according to material size and alloy. The entire layout of our ceramic tile area, whose ambient temperature and humidity are automatically stabilized at the most appropriate values, including the ventilation system, has been developed with new investments.
Wax Removal:
For dewaxing, the ceramic-coated clusters are placed in the pressure chamber of the autoclave system. By reaching a pressure range of 8-10 bar in a maximum of 5 seconds, it is ensured that the wax is removed from the ceramic shells with the effect of 180°C steam. Thus, damage to the ceramic shells caused by cracking is completely prevented. Thanks to the PLC controlled system, all working parameters of the wax melting system are kept under control and continuous recording and traceability is possible. Our fully automatic controlled autoclave system consumes minimum energy thanks to its steam conversion system.
Casting:
Casting of steel, stainless steel and bronze alloys is carried out in induction furnaces, and casting of aluminum alloys is carried out in electric melting furnaces. By eliminating the prejudice that the foundry is not clean, with the investments made and the control system established, a very modern foundry sector has been brought to our sector in terms of both occupational safety and working efficiency. Chemical analyzes are carried out with a spectrometer device before and after casting, and analysis control results are recorded and traceable. In addition to the features of our spectrometer device, we can also control the analysis of special alloys by detecting the amount of nitrogen in the steel. From non-ferrous materials to steel products; We are able to report a wide range of chemical analysis processes, from aluminum alloys to super alloys, in a controlled manner with reference samples in accordance with standards.
Ceramic Shell Breaking, Cutting and Zeroing:
The cooled ceramic shells are broken with special equipment and the pieces to be produced are cut and separated from the cluster. The pieces cut out of the cluster are subjected to finishing operations (deburring, cleaning, surface polishing-sandblasting) in order to remove the runners and excesses on them.
Mold Design and Production:
In order to provide the best casting parameters for the requested product, Unimetal uses the latest CAD technologies to supply the wax injection mold to its customers with competitively advantageous costs. Fixtures that provide and