ENGINEERING DEPARTMENT
Engineering department of the company works with the following software
AUTOCAD MECHANICAL 2011 and NX 8; 8.5

PATTERNS MAKING SHOP
The plant has its own patterns making shop, which guarantee their quality. The patterns are made of wood, epoxide resine or metal.

CORES MAKING SHOP
The cores are made on semi-automatic machines or are manually produced following the CO2 method.

MOULDING AREA
Depending on size of the castings the moulding process is completed in one of the follow moulding departments:

MACHINE MOULDING AREA
Dimensions of the moulding boxes: 1000х800х250/250 мм.,
Possibilities for the single weight of the castings:
from 10 kg to 300 kg

The moulding machines are Foromat 40

MECHANIZED AREA FOR MIDDLE DIMENSIONS CASTINGS
Dimensions of the moulding boxes: depending on the casting’s dimensions
Maximum load of the box is 300-5000 kg. for a serviceable casting

HAND MOULDING AREA
The hand moulding area is for middle and big dimensions castings, single weight of the part up to 6000kg.
Dimensions of the moulding boxes max. 5000x2400x1500 mm

Methods of moulding:
• СО2 with silicate supporters
• Alpha-set

MELTING SHOP
The foundry has the following melting capacities:
=> 1 x 8000 kg. and 1 x 5000 kg. electric arc furnaces
=> 2 x 1600 kg. induction furnaces It is used top pouring of the metal
The casting process is controlled by contact measurement of the temperature – by using submerged thermo couples

CLEANING OF THE CASTINGS AREA
The castings’ cleaning is done in shot blasting machines.
The rough cleaning is made by hand, with pneumatic guns, and the fine cleaning - in shot blasting drums and chambers with 2 mm grain size.

HEAT TREATMENT
The heat treatment possibilities in Metakom are determined by the available equipment in the foundry. The treatment is done in heat-treating chamber furnaces:
• 2 pcs. Gas furnaces having a 4900 x 2200x 1700 mm working chamber
• 3 pcs. Electric furnace having a 1000 x 900 x 1900 mm working chamber
• An Electric furnace having a 3000 x 2000 x 2000 mm working chamber
• An oil quenching bath having a 2000 x 3000 x 1000 mm size

The highest level of the heating temperature is 1100 C

MECHANICAL WORKSHOP
Metakom’s possibilities for a rough machining are as follows:
• dimensiones: 2800х1800 mm
• rotating configuration: up to d=2000 mm; d=500 mm and length of the part up to d=2500 mm
• machines with CNC

The large portfolio of steel and cast-iron grades as well as the wide range of products’ dimensions and single weights helps us in being highly flexible for satisfying our client’s requirements.

QUALITY
The quality of the production is guaranteed by means of:
• Spectral analysis
• Chemical analysis
• Metallographic analysis
• Physical – mechanical tests (tensile of strength, flow, prolongation, shrinkage, stressed strudiness and hardness by Brinel)
• Laboratory control of the moulding mixtures (tensile of wet and dry, gas-permeability, moisture content)
• Laboratory control of incoming materials
• Non destructive tests:
UT - ultra-sonic test
MT - magnetic field test
PT - penetration test