TAKE ADVANTAGE OF OUR

COMPREHENSIVE SERVICE

WE DESIGN
WE MODEL
WE PRODUCE
WE CLEAN
WE MACHINE
WE PAINT
QUALITY CONTROL
WE PACK AND DELIVER
What are your profits?
  • significant shortening of the castings production time – 3-5 weeks from technical records preparing to delivery of ready castings!
  • optimisation of production costs –the whole process is implemented in one place
  • product is ready for implementation- no necessity for additional machining, cleaning or painting
  • guarantee of the castings highest quality – due to implementation of the newest technologies and quality control in every phase of the process

WE DESIGN

Highly qualified and experienced engineering staff supported by young constructors prepares technical and construction records based on drawings or finished product delivered by the customer. Their task is also to define a model construction, selection of castings system, casting feeding and process metallurgical parameters. Technological process in developed based on the applicable PN-EN standards and ISO instructions. The modern CAD/CAE software are used for designs and simulations.

WE MODEL

On the basis of a construction file we perform new modelling of casting. For this purpose we use modern 3D CNC machine tools, we may also adapt existing models to technical conditions of our foundry.

  • Cast iron, steel of durability of 100 000 moulding
  • Aluminium of durability of 40 000 moulding
  • LAB Material of durability of 30 000 moulding

In Odlewnia Kutno we use one of the best simulation systems for castings- MAGMA5, which allows to anticipate the occurrence and localisation of any casting defects.

WE PRODUCE

Cast iron smelting and spheroidising

Smelting of initial cast iron is carried out in 3 induction furnaces OTTO Junker with capacity of 6 tonnes each. For cast iron spheroidising we apply a flexible line method (PE). Cast iron smelting in induction furnaces allows for obtaining any chemical composition of smelted metal and high repeatability of products.

Quality control at this stage includes examination of chemical composition, the initial materials used for smelting and smelted product are examined. In case of smelted product the examination is carried out on samples from furnace and pouring device. Quality control and control of hot metal composition are performed with the use of ATAS software and two spark spectrometers.

Cast iron smelting and spheroidising

Moulds are made with the use of bentonite mass technology. Moulding is performed with the use of automatic moulding machine:

  • horizontal SINTO with mould size 700x900x250 and 700x900x125
  • vertical DISA-MATIC with batch size 525×650 with possibility of automatic core feeding.

Moulding line DISA-MATIC is one of the newest machines of that type on the market. Its high performance allows for quick implementation of the orders. DISA-MATIC technology guarantees high quality and reliability of castings: improves their functional parameters, better shape and the structure of surface.

The cores produced for agriculture are made with the use of:

  • COLDBOX technology on core shooting machines- LAEMPE, FISCHER having their own mixing unit for core mass and HOTTINGER.
  • HOTBOX on core shooting machines by SINTO made in Japan.

The cores are characterised by good toughness and may be stored for a long period of time. Core boxes can be produced with a vertical or horizontal split.

Pouring

Pouring machines ABB and OTTO Junker are used to pour moulds. The pouring machines are equipped with inductor ensuring constant pouring temperature. Pouring od ductile cast iron is performed with the use of protective atmosphere of nitrogen.

WE CLEAN

Final castings go on machine tools: They clean elements, give them smooth shape and surface.

WE MACHINE

Own machining centre with CNC machine tools allows for machining of details by immersion on the basis of technical file submitted by the Customer and production of own modelling.

WE PAINT

Painting of castings is performed by an immersion method with waterborne and solvent-borne paints chosen in order to meet Client’s requirements.

WE PACK AND DELIVER

Finished castings are packed according to our Customers’ needs and delivered to the right place. We offer the following packaging methods:

  • Wrapped in foils on Euro pallets;
  • Euro pallets with upper sections;
  • wireboxes (gitterbox);
  • various metal and wooden containers;
  • individual packaging at the Customers’ request.

QUALITY CONTROL

At each stage of the production process we apply different quality control methods, which guarantee high quality and repeatability of the product’s parameters.

After cleaning every element undergoes a detailed visual control. We have own laboratory where the following examinations are performed:

  • chemical composition of initial materials and metal used in production,
  • castings microstructure,
  • tensile strength of cast iron Rm,
  • castings hardness HB,
  • impact (impact resistance) in a room temperature and negative temperature (-20 C),
  • non-destructive tests with the use of supersonic defectoscopes.

PRODUCTS

GREY CAST IRON

It has compression (3xRm) and tensile(300MPa) strength. It is brittle, well-machinable, demonstrates vibration damping properties and conducts heat efficiently.

We offer a wide range of grey cast iron grades

GRADE ACC. TO EN 1561

EN-GJL-150

EN-GJL-200

EN-GJL-250

EN-GJL-300

EN-GJL-350

GRADE ACC. TO DINN

GG-15

GG-20

GG-25

GG-30

GG-35

GRADE ACC. TO BS

150

200

250

300

350

GRADE ACC. TO NFA

FGL 150

FGL 200

FGL 250

FGL 300

FGL 350

RM MIN MPa

150

200

250

300

350

DUCTILE CAST IRON

Ductile cast iron with extension from 18 to 2%. The advantage of this ductile cast iron is its high tensile strength from 350MPa.

Odlewnia Kutno offers the following grades of ductile cast iron:

GRADE ACC. TO EN 1563

EN-GJS400-15

EN-GJS400-18LT

EN-GJS450-10

EN-GJS500-7

EN-GJS600-3

EN-GJS700-2

GRADE ACC. TO DIN

GGG-40

GGG-40.3

GGG-50

GGG-60

GGG-70

GRADE ACC. TO BS

420/12

400/18

450/10

500/7

600/3

700/2

RM MIN MPa

400

400

450

500

600

700

GRADE ACC. TO A5%

15

18

10

7

3

2

MOLYBDENUM CAST IRON
It is characterised by high temperature creep resistance and better yield and mechanical properties in comparison to ductile cast iron.

WG VOLVO STANDARD
STD 310-0004

VISG 510/10+AC/FSA/SR

stipulated yield strength
RPO2 [MPa]

410

Tensile strength Rm [MPa]

510

Elongation A5 [%]

10

PRODUCTS
Our offer includes castings of 0,3-61 kg made from grey and ductile cast iron, produced mainly at the Customers’ request. We provide full service- from a design, through modelling performance and castings production, machining and painting to completing and delivery.
We are offering several thousands of finished products for producers from various industries.

INDUSTRIES

Odlewnia Kutno produces castings for:
  • automotive industry
  • railway industry
  • engineering industry
  • manufacturers of agricultural and orchard machinery and tractors
  • manufacturers of water and industrial fittings
  • shipbuilding
  • mining and transshipment industry
  • aerospace industry
  • building industry
  • energy industry
  • Military Industry
  • power hydraulics
  • water hydraulics