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Neutral Expertise and R&D Review of Production and Operations
- OEM equipment performance analysis to maximize materials processing
- Furnace survey with thermal profiling
- Vibration and acoustic field diagnostics (add-on)
- In-field chemical measurements of castings and in-process materials
- Thermography (infra-red analysis)
Casting Process Optimization
- Solidification modeling to reduce casting imperfections/defects
- Mold and gating system design improvements
- Cycle time reduction and yield maximization
- Chemical distribution predictions and measurements
Alloy Development & Tailoring
- Custom alloy formulations for castability, performance, and cost
- Design of high-strength, wear-, and corrosion-resistant cast metals
- Sustainable alloy solutions to reduce critical elements, machining time, and cost
Defect Analysis & Troubleshooting
- Root cause investigation using proprietary field-proven algorithm
- In-field and lab metallographic evaluation and process diagnostics
- Recommendations for material and process corrections
Simulation & Modeling Services
- CAE tools for casting, heat transfer, and stress analysis
- Virtual prototyping to reduce floor trial-and-error
- Prediction of microstructure evolution and properties
Melt Practice & Refining Support
- Best practices for melting, inoculation, and alloying
- Control of impurities, inclusions, and gas content
- Furnace and crucible condition analysis
- Scrap analysis and purification guidance
Thermal Processing & Heat Treatment
- Design and validation of heat treatment cycles for castings
- Phase transformation control and hardening strategies
- Minimization of distortion and residual stress
- Solid-state evolution during processing
Sand System & Mold Material Evaluation (Add-on)
- Analysis and optimization of sand, binders, and additives
- Recommendations for core/mold selection and reuse
- Solutions for burn-on, veining, and erosion
Quality & Process Control Development
- In-process controls: thermal analysis, spectrometry, acoustics, vibration
- Statistical process control (SPC) and LEAN methods
- Traceability and data-driven quality systems
Sustainability & Waste Reduction (Add-on)
- Yield improvement via scrap reduction and process efficiency
- Reuse of return sand and by-products
- Support for environmental compliance and emission control
Training & Technical Coaching
- Hands-on or virtual foundry workshops
- Custom training in metallurgy, defects, process, and Industry 4.0
- Certification and technical development support
