Innovation. Commitment. Trust

INDUSTRIESSG

The new age Investment Casting plant has a total installed Production capacity of 600 Metric Tons per annum. Spread over 14000 sq. m. this modern and efficient manufacturing facility is equipped with the latest CAD/ CAM design & simulation software, machineries from reputed International brands and comprehensive in-house testing facilities.

SGI has capabilities to produce precision Ferrous and Non-ferrous Investment castings

The Integrated Superior Metallurgical process followed at SGI comprises the latest proven methods along with engineered Shell System - Faster Drying, Fewer Dips, less shell cracking and improved casting surface finish. This enables design and manufacture of any type of parts from 0.01grams to 60kgs and 5mm to 400mm size.

SGI has the process capabilities to produce precision parts that require little or no machining work. Castings can be in either ferrous or non-ferrous materials including all grades of stainless steel, high and low carbon steel and bronze and aluminum.

SGI is proud to have some of the industry’s best and experienced talents to manage its manufacturing operations. Whether it is the Regulator body, spring case, closed & opened impellers, Valve Housings, Shafts, Disc Brackets or Holding Plate every effort is made to ensure appropriate design, superior raw material, appropriate process coupled with global quality standards. SGI guarantees total support with single source responsibility from design through finished product. Our team of qualified professionals ensure that your casting has the highest quality possible.

SGI Product engineering team is constantly involved in study of various metal and alloys and evolves new techniques to improve process of investment casting. Custom designed solutions are provided in partnership with customer development teams. SGI capable to RE-ENGINEERING the parts in Investment Casting process from Sand Casting, Forging and Other Several Metal Forming processes.

ABOUT US........................................................................................

CAPABILITIESNORMAL LINEAR TOLERANCES - ISO 8062 | DCTG 6 | VDG - P 690 D2

DIMENSIONAL

Flatness & Straightness Flatness and straightness can be achieved 0.03 to 0.05 TIR per linear inch.

ConcentricityConcentricity can be achieved not more than 0.005 times the difference between the diameters in inches.

Radii & Fillets0.03” maximum corner Radius and 0.06” minimum fillet are recommended.

Wall Thickness:Minimum wall thickness is 2 mm.

Angular ToleranceAngular Tolerance of ± 1° is normal.

Machining Allowance0.5mm to 2.0mm wherever machining fitment is expected

Letter/Logo/NumbersRaised letter with maximum of 0.020”projection

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Ferrous & Non Ferrous Castings

0.01Kgs to 60Kgs Casting Weight

5mm to 400mm Casting Size

VDG P690 D2 All dimensions are in mm

Nominal Dimension Tolerance Zone

0 ≤6 0.16>6 ≤10 0.2>10 ≤14 0.24>14 ≤18 0.28>18 ≤24 0.34>24 ≤30 0.4>30 ≤40 0.5>40 ≤50 0.6>50 ≤65 0.76>65 ≤80 0.92>80 ≤100 1.06>100 ≤120 1.2

ISO 8062 DCTG - 06 All dimensions are in mm

Nominal Dimension Tolerance Zone

0 ≤10 0.16>10 ≤16 0.2>16 ≤25 0.24>25 ≤40 0.28>40 ≤63 0.34>63 ≤100 0.4>100 ≤160 0.5>160 ≤250 0.6>250 ≤400 0.76>400 ≤630 0.92>630 ≤1000 1.06>1000 ≤1600 1.2

ALLIED FACILITIES Rapid Prototying using 3D Printing/SRM/Flask Method/ Vacum Pouring Facilities to develop parts in shorter lead time.

Machining Facilities - CNC Turing/Milling & Gear Hobbing

Assembly and Fabrication Units to deliver customer special requirements.

Special finish - Painting/Powder Coating/Electro Plating and Electro Polishing.

CASEHARDENING STEEL

C10

16MnCr5

C15

18CrMo4

12NiCr3

18NiCrMo5

16CrNi4

18NiCrMo7

16NiCr11

20MnCr5

16NiCrMo2

20CrNi4

16NiCrMo12

20NiCrMo2

TEMPERING STEEL

C20

C50

32CrMo12

39NiCrMo3

C25

C60

34NiCrMo16

42CrMo4

C30

25CrMo4

34Cr4

40NiCrMo2

C35

C28Mn

35CrMo4

40NiCrMo7

C40

30CrMo4

35NiCrMo15

41Cr4

C45

30NiCrMo8

36CrMn5

50CrMo4

C55

30NiCrMo12

38Cr2

90Mn4

STAINLESS STEEL

AUSTENITIC (AISI)

201

304H

316L

317

202

304L

316H

317L

301

305

316LN

317LN

302

309

316N

321

303

310

316F

347

304

314

316Ti

304LN

316

316Cb

DUPLEX (UNS)

S32900 S31803 S32304 S32550 S32760

FERRITIC (AISI)

405 409 410S 430 430F 434 439

446

MARTENSITIC (AISI)

403 414 416 420 420F 422 431

440A 440B 440C

AUSTENITIC GRAY IRON - Ni Resist

NON FERROUS – ALL COPPER BASED ALLOYS

• SGI utilizes a system of tooling standards to ensure uniform high quality design and fabrication of wax injection dies which are guaranteed for the life of the part.

• Type of tooling:ManualPrototype or low volume production work.

AutomaticHigh volume, Parts that are too large or fragile for manual operation

• Configurations that do not allow metal cores in tooling to be drawn due to undercuts or complicated internal shapes must be treated in one of the following ways:

Collapsible Cores - Lowest piece price..

Loose Inserts - Best for low volume parts

Multi-Piece Wax Assemblies - Best for certain configurations, with wide tolerance

Soluble Cores & Pre-Formed Ceramic Cores - Provides excellent flexibility during shell building process at a moderate additional cost..

TOOLING

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CASTABLE ALLOYS AT SGI INDUSTRIES

• Equipped with precision CNC Machining Centers and CNC Gear Hobbing machines

• Machining QMS process certified with ISO/TS 16949:2009

• Capable and Stable process through Cp & Cpk studies

• Availability / Performance / Quality improves through OEE studies

• Machining of Parts from Forged Parts, Bar Rods, Investment Castings, Sand Castings, Pressure Die Castings, Gravity Die Castings.

MACHINING CAPABILITIES

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MACHINE TYPE / DETAILS TURNING MILLING GEAR HOBBING

Machine Stroke Length in mm

X 125 - 250 510 - 762 30 - 750

Z 195 - 1000 510 1000 Max

Y NA 510 250 Max

Options NA C Axis NA

Chuck Size in mm 165 - 400 NA NA

Gear Module NA NA 1 - 10

Number of Tool Stations 8 21 1

Number of Machines 20 5 7

MANUFACTURING FACILITY

• Solid Works and Master CAM for Mold Design and Machining Process

• Dual Injection Type PLC controlled Wax Injection Press.

• Soluable Core to form Intricate shape in single pattern.

• Imported Refractories and Binders shell system to meet Premium Quality

• Combination Mixing Procedure with High Shear Mixture and Jar Mill to obtain homogeneity of slurry.

• Auto Ambient Control Shell Drying Room with Special air feed provision to ensure optimum and uniform drying of shells.

• PLC controlled shell Sintering furnace.

• IGBT Induction Furnace with Argon Diffuser Setup.

• 1 Ton Auto Controlled Water Quenching Furnace with digital recorder.

• 1 Ton Auto Controlled Tempering furnace. (Normalizing & Annealing)

• Power Backup - 250KVA Diesel Generator.

• High Precision CNC TURING, MILLING AND CNC GEAR HOBBING Facility.

• Assembly and Fabrication Facilities - Allied unit

• Painting/Powder Coating/ Electro Plating/ Electro Polishing- Allied unit.

• RAPID PROTOTYPING (3D Printing/SRM/ Flask Technology/Vaccum Pouring).

• RE-ENGINEERING the parts in Investment Casting process from Sand Casting, Forging and Other Several Metal Forming processes.

QUALITY ASSURANCE

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INSPECTION

INSPECTION AND TESTING FACILITY

• Each tool is CMM inspected prior to issue onto injection floor ensuring compliance with customer’s specifications.

• We provide first piece wax inspection as well as final inspections to ensure that all pieces are conforming to the customer’s specifications.

• 100% Visual Inspection

• Dimensional inspection as per agreement made with customer

• Physical and chemical testing at various stages:

• Spectrographic analysis

• Wax Property analysis.

• Slurry quality analysis

• Mechanical properties like Tensile strength, Yield Strength, Elongation percentage, Reduction area, Hardness and Impact Testing

• Corrosion resistance Testing

• Radiographic, ultrasonic, and Magnetic Particle inspection are performed at local professional laboratories to ensure the soundness of quality.

• Process Control of Waxes and Slurries

• 2D/3D measuring device used for layout inspection.

• Ferrous & Non Ferrous Based Optical Emission Spectrometer – Brucker Q4 Tasman with Nitrogen - 35 Chemical elements can be measured

• Computerized Universal Testing Machine – 40T

• Optical Brinel Hardness Tester – 3000Kgf

• Rockwell Hardness Tester

• Izod/Charpy Impact Tester – IS & BS

• Process Material Analytical Lab

» Shell - Hot Air oven/Centrifuge/pH meter

» Wax - Muffle furnace

• Pressure Testing - Hydro & Pneumatic

• Surface Plate, Angle Plate and Between Center.

• Measuring instruments like Digital Height Gauge, Calipers, Micro meters, etc..

• Roughness Tester

• 3D Coordinate Measuring Machine

• Vision Inspection System

ISO 9001 - Quality Management System

ISO 14001 - Environmental Management System

OHSAS 18001 - Occupational Health and Safety assessment series

Casting Unit

Machining Unit

SYSTEMS

Pressure Equipment Directive.

ISO 9001 : 2008 - Quality Management System ISO/TS 16949 : 2009

• Automobile

• Agriculture

• Air Conditioning & Refrigeration

• Boiler Mountings & Accessories

• Defense

• Compressors Parts

• Crimping Tool Industries

• Cooling tower & chilling plants

• Diesel & Gas Turbine Equipments

• Dairy Equipments

• Electrical engineering Industries

• Earth Moving machinery

• Food Processing Machinery

• Hydraulic Products &Equipments

• Industrial machinery parts

• Marine Equipments

• Mining Equipments

• Industrial Pumps & pumping Equipments

• Textile

INDUSTRIES SERVEDDue to the advanced manufacturing process adopted at SGI, we are capable to manufacturing a comprehensive range of metal alloy castings. With our proficiency in this domain experienced team and Advanced Infrastructure, we can meet the diverse requirements of a wide variety of industries including

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Pondicherry

Bangalore

Hyderabad

Mumbai

Delhi

A

B

Chennai

Regd. OfficeNo. 104, S.V. Patel Road, Pondicherry-605 001, INDIA.Email : amar@sgalloys.com

Machining DivisionR.S. No.74/2B, Madukarai Main Road, Mangalam Pondicherry-605 110, INDIA. Phone: +91 413 2660733 I www.supremeautomech.comMobile: +91 9994458091 | jothi@supremeautomech.com

Investment Casting Division12/1A, Villianur Main Road, Uruvaiyar, Mangalam Post,Pondicherry-605110. INDIAPhone : +91 413 2970422 I www.sgalloys.comMobile : +91 9655249619 | Email : felixj@sgalloys.com

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SGI Industries located South of Chennai

• 150Kms from Chennai Airport

• 14Kms from Pondicherry Airport

• Robotics and Conveyorised Shell Room

• ISO 27001:2013 - Information Security Management System certification and

• Metallurgical Laboratory

LOCATION MAP

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INDUSTRIESSG