Product Design, Engineering & Development

The heart of any foundry is its melting capability. Our Furnace provides clean, efficient, and precisely controlled melting of a wide range of ferrous alloys. Induction melting offers several advantages — accurate temperature control, minimal carbon pickup, low energy consumption, and the ability to closely control the chemical composition of each heat.

We maintain strict charge calculation protocols and verify each heat through spectrometric analysis before tapping. Pouring is carried out by trained operators using pre-heated ladles, with temperature monitoring at the point of pour to ensure optimal filling of the mould cavity. Our process discipline ensures metallurgical consistency across batches, which is particularly critical for RDSO-approved railway components and other safety-critical applications.

Metal Grades We Pour

We employ the no-bake (chemical bonded) sand process for all our castings. In this process, sand is mixed with a chemical binder system (typically furan or phenolic urethane resin), which hardens at room temperature without the need for baking. This yields several distinct advantages over traditional green sand moulding:

Superior Surface Finish: No-bake moulds produce castings with significantly better surface quality, reducing or eliminating the need for extensive fettling and grinding.

Dimensional Accuracy: The rigid mould structure ensures tighter tolerances and more consistent dimensions, which is essential for machined and assembly-critical castings.

Complex Geometries: The process accommodates intricate core assemblies and complex shapes that would be difficult to achieve with green sand.

Casting Weight Range: Our moulding capability accommodates castings from approximately 20 kg up to 3000 kg per piece.

Cores are produced in-house using compatible resin systems, ensuring perfect assembly with the moulds. Our experienced moulding team works closely with the pattern shop to optimise gating, risering, and venting for each new casting, reducing defect rates from the very first production run.

Heat treatment is a critical post-casting process that determines the final mechanical properties, microstructure, and service performance of a casting. Our foundry is equipped with two dedicated heat treatment furnaces — an 8 Tonne and a 3 Tonne unit — allowing us to handle both large batch runs and smaller lots efficiently.

Heat Treatment Processes Offered

All heat treatment cycles are conducted with recorded temperature profiles, and treated castings are verified through hardness testing and, where required, metallographic examination to confirm that the specified mechanical properties have been achieved.

While our core strength lies in casting, we recognise that many clients require semi-finished or fully machined castings delivered to drawing specifications. Our machining facility is equipped with machining capability, enabling us to deliver castings with precision-machined surfaces, bored holes, threaded features, and dimensional finishes as specified.

Quality verification is not outsourced at ETA. Our in-house testing laboratory is equipped to carry out a comprehensive range of tests, ensuring that every casting meets the specified metallurgical, mechanical, and dimensional requirements before dispatch.

Testing Capabilities

All test results are documented and provided to clients as part of the material test certificate (MTC) accompanying each consignment. For RDSO and other third-party inspected orders, our laboratory supports inspection by RITES, RDSO inspecting officers, and client-appointed third-party agencies.