Karmen is a Tier 1 manufacturing partner for high integrity metal components produced from castings, forgings, or bar stock in ready-to-assemble fully machined and finished condition.
Be it simple machining with demanding Non-Destructive Testing (NDT) or complex machining coupled with value-added processes such as hard facing, lapping, or grinding – Karmen provides seamless solutions to their customers who are the world’s leading corporations in the valve, pump, oil & gas, energy, locomotive, and highway industries. Their exports encompass 10 countries across 3 continents.
MACHINED CAST PARTS – HIGH INTEGRITY METAL COMPONENTS
Karmen brings together over 4 decades of casting expertise to work for you in delivering optimal process and material selection. We do this through a combination of using our own state-of-the-art casting facility coupled with a select group of qualified foundry sources.
Sand or investment castings, ferrous or non-ferrous, Karmen is able to seamlessly deliver fully machined cast parts weighing a few grams to over 9000 lbs single piece is fully machined/finished condition.
Value-added special processes such as weld overlay / hard facing, lapping, and grinding form part of our regular production schedule. In addition, we have extensive experience and expertise with NDT (Non-Destructive Testing) including Magnetic Particle, Radiographic examination, Dye Penetrant, Visual and Ultrasonic Testing (MPI, RT, PT, VT, UT) to help you meet your inspection requirements. The NDT team is led by an ASNT Level III qualified person with over 40 years of experience ably supported by over 12 ASNT Level II certified NDT engineers.
While we specialize in low to medium volume production, we are equally capable of delivering high volume parts efficiently and cost-effectively.
Karmen is your one-stop preferred supplier for quality machined cast parts.
Sand 10 Lbs to 10000 Lbs
Carbon steels, Alloys, Stainless steel, Duplex stainless steel, Superalloys, Ductile iron
Investment 0.15 Lbs to 54 Lbs
Carbon steels, Alloys, Stainless steel, Duplex stainless steel, Superalloys, Ductile iron.
HIGH INTEGRITY STEEL CASTINGS
Karmen Castmetals, our state-of-the-art foundry started production in 2008 to meet the growing requirements of our global customers for high integrity steel, stainless steel, and super alloy castings.
The foundry located near Chennai, India is equipped with a fully automated molding line from IMF, Italy, and has a full-fledged material testing lab. On-site NDT facilities include Radiographic testing enclosure, Multi-directional magnetic particle crack detector, Ultrasonic testing facility, and in situ hardness test equipment.
Casting Design
- Pattern Making
- Patterns are sourced from experienced and capable pattern makers equipped with CNC pattern making capability.
Molding
- Two part Alkaline Phenolic sand binder system allowing tight as cast dimensional tolerance.
Pattern change station allows for pattern change over with zero downtime and efficient manufacture of single piece casting to high volumes. - Equipped with fully automatic IMF moulding line including transfer cars, roll over, mould heating ovens, mould pushers, shakeout and mechanical reclamation system.
- Mixer Capacity 25 tons per Hr and 8 Moulds can be made per hour.
- Equipped with latest Siemens S7 PLC Controls.
- Sand System: Alkaline Phenolic Resin System (Alphaset).
- Flask size 1800 x 1400 x 550 mm.
- Calculated capacity of moulding line is in excess of 450 MT per month.
- Melting & Pouring
- The plant is equipped with 1500 / 1000 / 500 Kg capacity Inductotherm Furnace.
Heat treatment
- 2.0 Tons Gas fired Heat treatment Furnace with Auto quenching facility.
- 2.5 Tons Gas fired Heat treatment Furnace with Auto quenching facility.
- 4.0 Tons Gas fired Heat treatment Furnace with Auto quenching facility.
- All of the above furnace are equipped with calibrated (API 6A) temperature recorders.
- Quench Tank with agitation facility equipped with temperature indicators and calibrated process monitoring and recording devices.
Fettling /Finishing shop
Fettling /Finishing shop works on the concept of single-piece flow. The modern fettling area is equipped with a hanger-type shot blasting machine, a Powered band saw cutting machine plasma arc cutting machine swing grinders, and welding equipment.
Precision Machined Components
As a value-added offering to our customers, we manufacture and supply high integrity “internal” that go into making their larger product.
They do:
From Bar Stock, Forgings and Fabrications
Open die closed die, and ring rolled forgings fully machined up to 1000 Kgs in a variety of alloy steel and stainless steels for the oil/gas/energy industries.
High precision machined components in a variety of materials grades including alloy steels, stainless steels, Inconel for the valve, locomotives, oil/gas, and energy industries.
Karmen Group
High Integrity Metal Components
DP 48 & 51 Sidco Industrial Estate,
Thirumazhisai,
Chennai – 602 107 India.
contact@karmengroup.com
Tel: +91-44-26810750
Fax: +91-44-26810753
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