Iron Foundry Division

The Cast Iron Foundry division represents a modern operation using advanced technologies for the production of castings from ductile and gray iron. The manufacturing process is controlled according to international quality standards. A significant part of the production is intended for the international automotive industry.

Certification

The Cast Iron Foundry division is certified according to EN ISO 9001:2015 and IATF 16949:2016 standards.

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Technological Equipment

Melting / Melting Shop

Two medium-frequency induction electric melting furnaces EGES 3 MW, MELT & HOLD type, with a volume of 2 x 4 t, melting performance of 6.1 t/hr.
Material charging is ensured by a vibrating cart shared for both furnaces.

Moulding

Frameless moulding line DISAMATIC 2013 LP/PLC-B, vertical parting line, size of sand moulds 535 x 650 x 120-360 mm.
Hourly capacity - technical - up to 300 moulds depending on the type of casting and the presence of cores; moulding mixture is prepared in 2 mixers with a capacity of 1-1.2 t, using return sand cooling.
Blast machine DISA DTC-2 with a polygonal drum.

Core Production

4 “Schalco” machines (hot box)
we purchase the mixture for core production.

Cast Materials

EN GJL 150, EN GJL 200, EN GJL 250, EN GJL 300
EN GJS 400-12, EN GJS 500-7, EN GJS 600-3, EN GJS 700-2

Optimal casting weight is 0.5-20 kg. The maximum size of the casting is limited by the size of the moulds.

Technical specifications of collaboration

Data processing - 3D documentation.
Modeling – drawing documentation, production of epoxy and metal models (core boxes) according to supplied pattern or 3D data.
Model production – most of it is manufactured by outsourcing – MOTOR JIKOV Foundry is responsible for positioning and feeding system, flow simulation is ensured by outsourcing if necessary.

Quality control of the material according to the technological flow

An optical emission spectrometer Q4 TASSMAN / manufacturer Bruker-Elemental / where chemical analysis of each melt is performed is located directly at the electric melting furnaces. Subsequently, a sample of the casting is taken from each melt, according to internal procedures or customer requirements, and tested in the laboratory for metallographic and mechanical properties.

Laboratory Capabilities and Equipment

Chemical Analysis

optical emission spectrometer SPECTROMAX, SPECTRO A.I. Kleve.

Metallographic Testing / Macrostructure and Microstructure of the Material:

preparation of cut-off samples on a semi-automatic grinder / polisher Buehler.
inverted metallographic microscope
NIKON ECLIPSE MA100 (50x – 500x),
NEOPHOT 32, Carl Zeiss (50x – 1000x).
ability to evaluate structure using image analysis in NIS-Elements program

Mechanical Tests:

hardness tests according to BRINELL, ROCKWELL, WICKERS
universal hardness tester KB Prüftechnik / 4.903 -2451 N
BRINELL hardness tester WPM Leipzig / 7355 N
ROCKWELL hardness tester Škoda Plzeň / 98.7 N – 1839 N
WICKERS hardness tester ZWICK / 1.961 N – 98.07 N
tensile test:
tearing machine EDZ 20, VEB WPM Leipzig. / 200 kN.

Hardening Shop

Mechanical Equipment

Multifunctional SOLO line with protective atmosphere
Batch dimensions: 400 x 400 x 600 mm, weight max. 110kg
Trolley chamber annealing furnace (without protective atmosphere)
Trolley dimensions: 1700 x 880 x 850mm, weight 1000 kg
Induction hardening

Heat Treatment Technology

soft annealing
stress-relieving annealing
hardening up to 930°C
tempering
case hardening up to 1.4mm
nitrocarburizing
VF hardening up to 55mm in diameter

Quality Assurance

surface hardness control, hardness profile in cross-section, depth of case-hardened layer in the lab.
ability to issue ČSN EN ISO 10204 inspection certificate

Products

Cardan joint castings
Components of industrial gearboxes
Stabilizer brackets for passenger cars
Castings for crane systems
Axle parts for industrial vehicles, control elements, brake drums
Castings of specific parts (bodies, flanges, hubs, brackets)

MOTOR JIKOV Engineering a.s. Iron Foundry Division