Comprehensive Foundry Engineering Solutions in TURKEY

Borematic +Cope offers tailored foundry engineering and CNC machining solutions, addressing the critical need for high-quality casting and machining in global supply chains. With the support of experienced metallurgical and materials engineers and quality engineers, we work closely with suppliers (foundries) to deliver optimized processes, defect-free components, and reliable quality assurance for international customers.

Material Selection and Metallurgical Expertise

Proper material selection is the cornerstone of successful casting. Borematic’s team evaluates material grades to match performance requirements, including mechanical properties, corrosion resistance, and machinability. Key materials include:

1. Gray Iron
   • EN GJL-150, EN GJL-200, EN GJL-250, EN GJL-300: Ideal for applications needing vibration damping and wear resistance, such as engine blocks and machine bases.
2. Ductile Iron
   • EN GJS-400-15, EN GJS-500-7, EN GJS-600-3: Perfect for structural and dynamic applications, including gears, crankshafts, and suspension systems.
3. Aluminum Alloys
   • A356 (T6): For lightweight, high-strength applications like automotive and aerospace components.
   • A380: Widely used in die-casting for housings, brackets, and electrical enclosures.

Borematic’s engineers ensure alloys meet customer specifications by conducting chemical analysis, verifying compliance with standards like ISO, ASTM, and EN.

Core-Making and Mold Design

Core and mold quality are critical to casting success. Borematic meticulously supervises these processes to prevent defects:

1. Core Production and Painting
   • Core Sand and Binder Selection: Optimized for strength, permeability, and collapsibility to avoid gas entrapment and ensure easy core removal.
   • Core Painting: Application of refractory coatings ensures smooth internal surfaces, minimizing turbulence and preventing erosion during molten metal flow.
   • Curing and Inspection: Uniform curing is validated to ensure dimensional accuracy and structural integrity under high temperatures.
2. Mold Design and Preparation
   • Resin-Bonded Sand Molds: Used for precise and durable mold cavities in complex geometries.
   • Green Sand and Dry Sand: Green sand molds for cost-effectiveness and dry sand molds for large, intricate castings.
   • Gating System Optimization: Proper placement and sizing of gates, risers, and runners ensure uniform molten metal flow, preventing cold shuts and misruns.
3. Gas Ventilation
   • Designing molds with optimized vents to eliminate trapped gases, reducing defects like porosity and blowholes.
   • Employing permeable mold materials and venting cores for efficient gas escape during pouring.

Pouring, Solidification, and Post-Casting Processes

Borematic ensures precise control during pouring and solidification to achieve consistent quality.

1. Molten Metal Control
   • Degassing and Filtration: Eliminating gases and inclusions for cleaner, defect-free castings.
   • Temperature Monitoring: Maintaining ideal pouring temperatures to avoid thermal stress and structural defects.
2. Solidification Analysis
   • Using advanced simulation tools to predict solidification patterns, allowing for optimized riser placement and defect mitigation.
   • Designing feeder systems to address shrinkage, ensuring void-free components.
3. Post-Casting Treatments
   • Heat Treatment: Tailoring annealing, normalizing, and quenching processes for the desired microstructure and mechanical properties.
   • Surface Cleaning and Finishing: Ensuring smooth surfaces and removing casting residues with shot blasting, grinding, or machining.

Defect Prevention and Inspection

Preventing and identifying defects at every stage ensures superior casting quality:

1. Defects Addressed
   • Porosity and Gas Defects: Prevented through proper ventilation, degassing, and low-gas binder systems.
   • Shrinkage and Voids: Mitigated using precise riser designs and gating system optimization.
   • Cold Shuts and Misruns: Avoided by maintaining consistent molten metal flow and adequate thermal control.
2. Inspection and Testing
   • Non-Destructive Testing (NDT): Radiographic, ultrasonic, and magnetic particle testing for internal defect detection.
   • Dimensional Verification: Using tools like Coordinate Measuring Machines (CMM) to ensure exact tolerances.
   • Mechanical Property Validation: Hardness, tensile strength, and fatigue testing confirm performance standards.

Role of Borematic Engineers in Supplier Collaboration

Borematic’s experienced team of metallurgical, materials, and quality engineers collaborates directly with foundries to oversee and improve processes. Key contributions include:

1. Process Optimization
   • Evaluating and standardizing foundry operations to improve efficiency and reduce costs.
   • Implementing advanced casting simulations to preemptively address potential issues.
2. Quality Assurance Oversight
   • Monitoring compliance with international standards like ISO 9001 and EN specifications.
   • Providing comprehensive documentation for traceability, ensuring confidence for international buyers.
3. Supplier Training and Support
   • Training supplier personnel in advanced casting techniques, defect analysis, and quality management systems.
   • Offering technical guidance on adopting innovative technologies for better production outcomes.

CNC Machining: Precision and Reliability

In tandem with foundry services, Borematic ensures CNC machining processes maintain tight tolerances, exceptional surface finishes, and consistent quality. Key services include:

1. Process Validation:
   • Reviewing CAD/CAM models for optimal machinability and cycle time reduction.
2. Inspection and Quality Control:
   • Using precision instruments like CMM for dimensional checks.
   • Performing surface roughness and hardness tests to meet application requirements.

Why Choose Borematic?

Borematic offers unparalleled expertise, ensuring customers receive high-quality products through meticulous engineering and robust quality control. With localized knowledge of Turkish suppliers and a commitment to international standards compliance, we guarantee reliability, efficiency, and peace of mind for global clients.

Contact Borematic +Cope to discuss how our services can elevate your supply chain with defect-free, precision-engineered components.