Casting Division

Harihar Alloys Private Limited started out as a small casting shop manufacturing Carbon Steel, Low Alloy Steel, Stainless Steel, Super Duplex Stainless Steel, Nickel Alloy Castings for various industrial and valve manufacturers. With increase in demand over the years, Harihar expanded the manufacturing capacity by establishing additional plants and investing in newer technology.

Currently, Harihar's Casting division comprises of two manufacturing units namely Unit-I and Unit-II.

The modernized plant, Unit-I with indigenously developed innovative technology is situated 26 kms away from Tiruchirappalli with a total area of around 8 acres and a working area of 35000 sq. feet. The Unit-II is located in Laxmanampatti village, Pudukottai district with a total area of 5.64 acres and working area of 61435 sq. feet.

The facility has an installed manufacturing capacity of 8000 T/annum with maximum single piece weight of 2700 kgs. The maximum size of Valve casting produced is 36" valve body.

The following are the facilities available at casting division:

Pattern Shop

A pattern is a reproduction of the object to be cast, used to make the cavity into which molten material will be poured during the casting process. The quality of the castings is highly dependent on the pattern and special care is taken to develop and to restore them after each usage. Highly skilled pattern designers and helpers are employed to maintain and retool the patterns. Patterns used in our process are usually made out of Wood or Aluminium. Both casting units have dedicated pattern shops for quick turnaround.

Developnment

Harihar has strong work force to simulate the Castings using desired software MAGMA to review the Methoding modifications to ensure 100% defect free Castings.

Melting Process

Electric Induction furnaces are used in our melt shop. Induction furnace produces uniform alloy due to the mixing created by the induction field. With help of chemist and state-of-the-art spectrometer, we insure precise alloy compositions.

Our production facility consists of 10 furnaces including a high capacity 3000 kg furnace.

Moulding Process :

The IMF moulding process employs a moulding mixture of silicon sand with appropriate combination of Hardner & Resin. The resulting mixture is filled in the mould boxes using machine filler and moved for Heating. The used sand is reclaimed for environmental considerations and to keep the costs low.

The carbon dioxide moulding process employs a moulding mixture of sand and liquid silicate binder. The resulting mixture is hardened by blowing carbon dioxide gas through it. The used sand is reclaimed for environmental considerations and to keep the costs low.

The following are some of the equipment in use:

  • Sand Muller
  • Sand Mixer
  • Moulding Machine
  • Core Oven
  • Sodium Silicate Oil Pumping Motor
  • Sand Sieving Machine
  • Moulding boxes
  • Spray unit

Fettling Process :

In wide expansion, Harihar has expanded a separate Bay for Fettling of Stainless Steel Castings with required infrastructure to satisfy the Customer Needs.

Fettling is the process of cleaning the casting remnants such as riser, runner and other excess material. This is considered to be the first stage of finishing.

This is a labor intensive process and in-house personnel handle the first stage of preliminary cutting. The final finish is achieved by swing frame grinding & hand grinding and is done at reputed vendor locations. Templates are used to maintain dimensional accuracy.

Shot blasting & Sand Blasting is carried out in between the stages to get the desired finish.

Heat Treatment Facility:
  • Oil fired furnace with highest capaity of 10 Tons
  • Oil fired furnace of 3 Tons with Automatic Quenching
  • Oil fired furnaces with capaity of 8, 7 & 5 Tons
  • Electric furnace
  • Water quenching tanks
Testing Facilities
  • Optical emission spectrometer
  • Carbon testing apparatus
  • Muffle furnace
  • Universal testing machine
  • Brinell hardness tester
  • Impact testing machine
  • Profile projector
  • Sand testing equipment
  • Lateral expansion gauge
  • Radiographic testing equipment
  • Fluroscent Magnetic Particle Examinationt
  • Liquid penetrant inspection accessories
  • Rad Check Meter
  • Positive Material Identification Equipment
Machine Shop
The facility is supported by experienced design engineers, machinists and fully equipped tool room...
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Forging
The unit has manufacturing capacity of 9000 MT per annum and can manufacture single piece forged components...
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Over view of Raw materials
Proper inventory management of raw material plays a significant role in on-timey...
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Quality Policy
Proper inventory management of raw material plays a significant role in on-timey...
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