Vishal Foundry have 3 stages of Quality inspection.
1) Incoming inspection
At Vishal Foundry Incoming inspection is carried out for every
batch of major raw material and consumables like:
- Pig iron
- Mild steel scrap
- CRCA scrap
- Silica Sand
- Mold paints
- Bentonite
Note: All the tests are conducted in our lab. We do not
buy recycled casting scrap for our castings at all as there is
risk of unwanted elements getting into the final chemistry. We
rely on the inspection certificates for all the alloys used in
the casting bought from standard suppliers in the market.
2) In-Process inspection
In-Process inspection is carried out for all the processes as
per control plan of the quality manual like:
-
Mold hardness inspection for every mold using
portable mold hardness tester.
-
Core scratch hardness inspection using scratch
hardness tester.
-
Core gas determination to detect gas formation
after pouring in the mold.
-
Sand properties like Compressive green strength,
permeability, moisture%, Loss of ignition, Volatile
matter, AFS size and clay content is tested in our
exclusive sand lab.
-
Metal properties like metal chemistry before and
after pouring with an In-House Spectro meter, Metal
temperature during tapping and pouring using an
Infra-Red non-contact type pyrometer. We also use Carbon
silicon analyzer for cross verification of chemistry.
3) Final inspection
Final inspection is carried out within the setup for every
heat poured:
-
Chemical properties of castings using the
In-house Spectrometer.
-
Mechanical properties of the casting like
Tensile strength, Elongation and Yield strength using an
In-house Tensile testing machine.
-
Hardness testing of castings with a hydraulic
BHN machine, Poldi tester and Electronic Dynamic
hardness testing machine.
-
Micro structure analysis using a microscope and
image analyzer software. We can provide all the final
inspection report compiled in a standard format to the
customers for every heat number poured related to the
casting supply.
-
Casting dimensional inspection : Finally, the
castings are dimensionally inspected randomly in regular
intervals before dispatch. 100%-dimensional inspection
is carried out for the new development for first sample
approval procedure.
Foundry related test Reports
-
We provide foundry test reports as per A 3.1 EN 10204
Certificate of compliance to a standard for the
material, with every batch of castings poured.
-
We provide casting dimensional test reports for the
first article inspection.
Vishal Foundry have 3 stages of inspection in our machine shop
similar to the foundry.
1) Incoming inspection
We check 100% incoming raw and machined components that enter
our machine shop to confirm the following parameters:
-
Visual defects in raw castings before starting the
machining process.
-
If machining is outsourced or pre-machined the
dimensions are checked 100% before moving the component
for further processing.
-
Assembly child part inspection is done according to the
control plan for frequency and specifications of the
particular child part.
2) In process inspection
We do inspect the processes every batch for the process
related errors like GD&T. First component is checked for
dimensional variation after every setup change on each machine
or process or machining. If in doubt we also verify the
components for critical parameters like GD&T using
external CMM facility.
3) Final inspection
Final inspection is carried for components according to the
inspection frequency of the particular component as per
control plan like:
- Dimensional accuracy with respect to drawing.
-
Hydro testing of the pressure rated component as per
maximum working pressure for 100 % of the components.
-
Inspection of visual defects, foundry related defects,
dents, chatter marks etc. is carried out before the
components move for dispatch crossing the inspection
fire wall.
-
Assembly inspection for, hydro testing, assembly working
inspection etc.
-
Packing inspection is done for all the packages leaving
the warehouse for any defects related to the packaging
for Exports or domestic shipments.
-
Pre-Dispatch inspection is done to check all the related
technical and commercial documents are provided before
the shipments leaves the warehouse as per the
instruction in purchase order.
Machine shop related test reports
-
Dimensional inspection reports of components according
to the inspection frequency of control plan.
- Hydro test report as component pressure rating.
-
Assembly inspection report as per assembly drawing
requirement.
-
CMM reports for GD&T for first article inspection or
if there is change in machining process.
