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Process Engineering

Advanced foundry process engineering — precision metallurgy, heat treatment, and continuous improvement.

Foundry Excellence

Mastery of the Entire Casting Process Cycle

Process engineering is the backbone of our quality guarantee. Our metallurgists and process engineers oversee every stage — from charge preparation and melt chemistry control, through pouring, solidification, and knockout, to heat treatment and final surface finishing.

By maintaining in-house control over the complete process cycle, we achieve consistent metallurgical properties, batch-to-batch repeatability, and the ability to meet the most demanding alloy specifications for critical infrastructure applications worldwide.

1200°C
Max Temp
2500kg
Max Pour
15+
Alloy Types
Automated Sand Moulding at APC Foundry
Process Steps

Our Controlled Manufacturing Process

Charge Preparation & Melting

  • Verified scrap and alloy inputs
  • Medium frequency induction furnaces
  • In-furnace OES spectrometer analysis
  • Argon purging for clean metal

Moulding & Pouring

  • Automated green sand moulding
  • Furan and shell moulding
  • Pouring temperature control ±10°C
  • Simulation-verified gating system

Heat Treatment

  • Full annealing and normalizing
  • Quench & Temper (Q&T) cycles
  • Solution annealing for stainless
  • Hardness verification post-treatment

Cleaning & Fettling

  • Knockout, shot blasting, grinding
  • Gate and riser removal
  • Weld repair per ASME IX / ISO 3834
  • Post-weld heat treatment (PWHT)

In-Process Inspection

  • Dimensional checks at each stage
  • NDT at critical process points
  • Hold points for customer witness
  • First-piece and batch approval

Packing & Dispatch

  • Rust preventive coating / VCI wrap
  • Seaworthy wooden crate packing
  • ISPM 15 heat-treated timber
  • Full documentation package
Our Facility

Process Engineering in Action

Sand Moulding Process

Sand Moulding Process

Green Sand Casting

Green Sand Casting

Investment Casting

Investment Casting

Casting Simulation

Casting Simulation

Alloy Selection

Alloy Selection

Rapid Prototyping

Rapid Prototyping

Chemical Testing (OES)

Chemical Testing (OES)

Tensile Strength Testing

Tensile Strength Testing