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Forge and Foundry

Forging

Forging is a method of manufacturing metal parts/pieces and consists of the plastic deformation of a metal, caused by stress being applied to the metal, either by impact or pressure. In this process the metal flows in the direction of least resistance, thus, in general, causing a lateral elongation, unless the process is contained.

We perform open forging using copper, and its alloys, to manufacture a wide range of products for a variety of industries. In this way, these forged parts attain a high level of quality and precision. Moreover, we can perform low-cost procedures helping you to produce your required products to your specifications (bars, rings, and discs) with the security that the products will be of optimum quality, whilst also providing competitive prices for the marketplace.

Foundry

In Etal, we offer you the indicated forging services for the production of diverse forms of solid metal parts. The molten metal is poured into a mold and then left to solidify in the shape of the cavity of the mold.

This type of casting offers an exceptional level of freedom with regard to the type of pieces produced. Additionally, this process is perfect for large-volume production of parts, whereby the quantity of material can be controlled efficiently, thereby reducing the amount of waste and, in turn, reducing costs.

 

Forge and Foundry

Types of casting in Etal

Sand molding

In Etal, we work with green-sand casting, using copper and its alloys to manufacture a wide range of products for a variety of industries. The castings used in this technique offer both high-quality and precision results. Likewise, we can produce your pieces under low-cost structures by developing the products according to your specific requirements with the added security of offering optimum quality at competitive market prices.

This process is characterized by using sand as the mold material. The molding sand is typically mixed with a bonding agent (such as clay) and dampened with water, or some other liquid, so as to create the adequate strength and plasticity. The mold cavity is created by compacting the sand in a mold box around the required model part. The model is then removed and the molten metal is poured into the newly formed cavity, then left to cool, prior to removing the mold and revealing the final cast of the part.

Installed capacity

  •     Induction furnaces of 100, 250, 400 and 800 kg

  •     Sand-molding system for low volume (1 to 300 pieces)

  •     Sand-molding system for high production (5,000 pieces or more, depending on your requirements)

Permanent molding for copper parts

This process consists of a casting method in which the molten metal (in this case copper) is poured into a mold composed of the joining of two hardened dies, thus forming the cavity of the mold. Once the metal is poured and cooled, the dies are separated and the cast is ejected. Permanent die casting can achieve high dimensional accuracy, complex detail, and smooth casting surfaces that require minimal additional machining.

Our permanent mold process utilizes casting machines, thus reducing material waste and allowing you to produce superior quality parts. The molds used in this method are manufactured within Etal's workshop. This method is used exclusively for high-conductivity electrolytic copper to produce large volumes, with batches ranging from XX to XX,000 pieces..

Types of forging in Etal

There are two types of forging: open and closed. In open forging, the metal is not completely enclosed in the die (cast). For example, hammer forging is one of the characteristic forms of this method. The piece is formed due to the rapid and successive blows of the hammer.

Closed matrix forging is commonly used for high-level production. In this process, the metal is shaped by being pressed between two dies. The upper die is generally fixed to the ram of a forging press or hammer, whilst the lower die is secured to the anvil; together, these parts form the closed matrix. This method enables the production of highly complex pieces and offers great precision, along with a quality finish.

The basic applications and fields of use for open and closed forging are as follows:

  •     Open forging: the production of heavy pieces with high tolerance, in small and medium batches.

  •     Closed matrix forging: the production of precision pieces with reduced weight, in batches of between 1,000 and 5,000 units.

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