Project Time: Nov 2021

Project Location: UAE

Inquiry Products: 48 PCS Alloy Shredder Bars

Weight: 404kg per pcs

ZEN is a leading supplier of commodities, industrial metals, and machinery to Africa and the World. They have long historical relationships with dominant market players in Africa. Their track record of procuring, supplying, and delivering to our customers is evidenced by their substantial growth in volumes.

We meet ZEN at the 2018 Bauma Fair. After visiting Hunan JY Casting, we had started to cooperate in shredder wear parts (shredder grates, hammers, and caps), crusher wear parts (cone crusher liners, crusher jaw plates, crusher blow bars), and other manganese steel casting wear parts area.

Requirements

Process	Characteristics	Process Reqmt	Measurement	Product	Product REQ.	Quality Record
Moulding	1. Sand Strength 2. Mould & Core hardness 3. Rising 4. Gating 5. Chills 6. Flow off 7. Pouring time	As per checklist of ACCDD-006	1. UTS Machine 2. Scratch Hardness Tester 3. Method Card 4. Method Card 5. Method Card 6. Method Card 7. Method Card 8. Method Card	In Process Casting	As Per ASTM-802 Scrata 1. Surface Roughness-A2 2. Non-Mett Inclusion-B2 3. Gas Porosity-C2 4. Laps & Cold Shuts-N.A 5.Scabb-N.A 6. Hot Tears-N.A	Closing checklist ACDD-006
Melting	Chemical Composition	C=0.40-0.45 Si=0.40-0.60 Mn=0.80-1.00 S=0.035 max P=0.035 max Cr=0.90-1.10 Mo=0.30-0.40 Ni=0.80-0.90	By Spectrometer	In Process Casting	C=0.40-0.45 Si=0.40-0.60 Mn=0.80-1.00 S=0.035 max P=0.035 max Cr=0.90-1.10 Mo=0.30-0.40 Ni=0.80-0.90	Melting Log Sheet
Fettling	Minimum K/Out Time Riser K/Off	As per standard knockout time	By time & date of pouring VS Knockout time & Date visual	In Process Casting	As Per ASTM-802 Scrata 1. Surface Roughness-A2 2. Non-Mett Inclusion-B2 3. Gas Porosity-C2 4. Laps & Cold Shuts-N.A 5.Scabb-N.A 6. Hot Tears-N.A	Knock out report
Heat Treatment	Heat Treatment Cycle	Annealing heating rate ＜100℃ Soaking temperature 950℃±20℃ Soaking time 1.5 hours per inch Furnace cooling up to 200℃ then air cooling	Thermocouple temperature recorder	In Process Casting		Heat treatment log sheet & graph
Finishing	Swing frame grinding Hand grinding	Casting Dimension	Scale, Gauges & Template	In Process Casting	Casting Dimension
Casting Internal Inspection	DYE Penetrant Test	As Per EM 1371-1997	Visual		Under riser, ingates and corners Severity level Non Linear indication-SP2-CP2 Linear indication LP2c-AP2c	D.P.Report
	Magnetic Particle Test	As per EM 1369-1997	Visual		100% Area Severity Level Non linear indication-SM2 Linear indication LM1c-AM1c	M.P.I Report
	Ultrasonic Test	As per ASTM A609	Ultrasonic Machine		100% Area, Level 2	U.T. Report
Mechanical Properties	Hardness on casting surface	As Per ASTM A370	Portable hardness tester	In Process Casting	280-320 BHN	Hardness Test Report
Dimension Inspection	Dimension and Tolerance	Casting Dimension	Scale, Gauges & Template	In Process Casting	Casting Dimension	Inspection Dimension Report
Painting	Type of paint and area	Red color	Visual	Painting Casting	100% area, surface appearance