LABORATORY FACILITIES AND TESTING EQUIPMENT

LaboratoryTesting

We use microscopic inspections, spectroscopy chemical analysis , Brinell hardness , UTM, X-ray (Out sourced), sand testing, Ultrasonic(Nodularity confirmation),and other techniques to ensure customers receive quality products.

- Chemical Analysis

1.   Spectrometer , SpectromaxX,Germany make with 27 elements,capable of analyzing all forms of ductile iron,gray iron steel,and other raw materials
2.   Three nos. CE analyser showing Carbon,Silicon & Carbon equivalent.

- Metallurgical

1.   Fully equipped metallurgical laboratory with image analser.

- Sand Laboratories

1.   Fully equipped metallurgical laboratory with image analser.

- Engineering & Technology

1.   CAD drawings may be provided by customer using AutoCAD,

- Inspection & Testing Equipment

1.    Five nos. Brinell Hardness tester.
2.    Ultrasonic Thickness gauging for Nodularity confirmation.
3.    Inhouse layout facility.
4.    Co ordinate Measuring Machine (CMM), Brown & Sharpe make.
5.    Dynamic Balancing Machine

LIST OF TESTING PROCESSES IN MANUFACTURING A COMPONENT

INCOMING MATERIAL INSPECTION:

To produce castings of good quality to satisfy our valued customer , the quality of raw materials used very important. Consequently at Pillaigroup , great emphasis is laid on the quality of not only the finished product, but the materials that go into the manufacture of a product as well. As per policy, Pillai group conducts a high precision quality control procedure to check every input material at various intervals. This procedure ensures that Pillai group products are made with raw materials that are inspected and cleared for production.

MS Scrap, Pig Iron , CRCA bundle , Ferro alloy's , carbonaceous material , bentonite are some of the major raw material used by us which were checked inhouse/outside to verify its quality.

IN PROCESS CHECKS:

The various stages of manufacturing are closely monitored and controlled in order to produce quality castings.

Liquid metal:

1.   Chemistry of liquid metal checked by spectrometer - cleared by chemical lab.
2.   Tapping temperature checked by immersion pyrometer- cleared by chemical lab.
3.   Additions of nodulariser& inoculant done- by chemical lab.
4.   First box pouring temperature checked in every ladle.
5.   Count down timer set at 540 sec used to avoid fading & low temp.
6.   Micro coupon poured on last box checked for nodularity & clearance given for the heat.
7.   Chill depth checked for grey iron for machinability.
8.   Mould filling time checked.

Prepared GreenSand:

1.   Properties checked every hour: Green compressive strength, compactibility, moisture, permeability.
2.   Properties checked every day :Volatile matter ,Loss on ignition, active clay, total clay, dead clay.
3.   Additional checks also carried out if required .

On mould:

1.   Mould hardness 100% is checked for each & every mould.
2.   Set up sample verification is done for first mould of every item for the day.
3.   Core setting checking gauges are used for every mould.

Core making:

1.   Scratch hardness testing is done on initial run.
2.   Viscosity of core wash is checked.
3.   Gauging of cores wherever required is performed.
4.   Visual inspection of all cores for perfect baking.

Final product validation:

1.   There is a defined inspection plan for every item
2.   Layout inspection plan is made & followed
3.   Hardness checking done for 100% of critical components of pearlitic - ferritic grade nodular iron if required by customer other wise 20% of per heat checked to verify.
4.   ProductAudit at dock done for component as per plan made.
5.   Non destructive testing is also performed:
6.   Crack detection using spray method.
7.   Ultrasound testing to control internal soundness of the casting
8.   Ultrasonic thickness testing for predict nodualarity of the machined components

TROUBLESHOOTING & PROBLEM SOLVING:

To resolve problems  Pillai Group uses QC tools effectively