What we do
ZML Cast Iron produces castings in gray and ductile cast iron of medium and large volumes. The use of cutting-edge software makes it possible to anticipate and solve eventual problems in advance, reducing the time required for developing and starting up series production of new, particularly complex components.
We always pursued the policy of continuous improvement and Quality and Process Management complies with the standard required by the automotive supply chain in compliance with the regulations governing the Environmental Management System.
Processes
The first stage of the process takes place in a modern melting shop equipped with four electric induction furnaces, with a total capacity of 26 tonnes and a total installed power of 18 MW.
The charging of metallic materials and ferroalloys is fully automated, as is the handling of the downstream ladles used to transport the molten iron. The automated system is integrated with a metallurgical process control system which, through the analysis of the solidification behaviour of molten iron samples taken at the various stages of the process, makes it possible to achieve and maintain stable, controlled metallurgical properties of the castings produced.
The castings are produced on three moulding lines, each equipped with automatic pressure pouring furnaces which minimise contact with air and provide maximum control over pouring temperature and metal flow.
Each production line consists of a fully automatic vertical green-sand moulding machine, a dedicated moulding sand preparation plant, a cooling and shakeout line, a gating-system removal line, and a shot-blasting plant equipped with a sorting conveyor.
The production lines :
• Two vertical moulding lines in 600 × 480 × (120 + 330) mm flaskless
• One vertical moulding line in 850 × 650 × (200 + 400) mm flaskless
Complex castings incorporating internal passages are processed in automated robotic systems, where dimensional and shape checks, grinding and shot blasting of the internal passages are carried out. To ensure thorough internal cleanliness, the passages are inspected using endoscopic probes.