Zenith Allmart Precisindo LLC

Jalan Raya Krian Mojokerto, No. 168, 61263 Sidoarjo
Indonesia

Hall map

NEWCAST 2019 hall map (Hall 14): stand B07

Fairground map

NEWCAST 2019 fairground map: Hall 14

Our range of products

Product categories

  • 01  Ferrous castings - Iron, steel and malleable foundries
  • 01.02  Production processes
  • 01.02.004  Investment casting

Our products

Product category: Investment casting

Gating System of Investment Casting

Our first article made investment casting seems so simple, as if you only need to make wax pattern, make mold, melt metal, and pour the metal into the mold. Unfortunately, the actual metallurgy practice is more complicated than that. This article helps understanding: How to design gating system for precision casting?

First, let’s discuss about investment casting mold. The functions of the mold are the delivery of metal liquid and the shaping of final product. The mold is only used once and is disposable after the casting. Look into our previous article to refresh about precision casting process, especially mold production which result in negative cavity for metal filling. As already mentioned in the previous article, the cavity forms after the lost-wax process. Before filling the cavity, liquid metal passes through gating system to optimize metal delivery and improve the product casting quality.

More Less

Product category: Investment casting

Gating System

Liquid metal adapts to the shape of mold cavity. This is the reason metal casting has been popularly used. Product shaping is possible regardless of shape complexity as long as liquid metal can properly fill the mold. Nonetheless,the design of the mold requires more than the shape of the product.

Proper mold design makes cutbacks in problems associated with investment casting. During the mold design, you need to draw more than just the products, but also their gating system (metal delivery system) to result in high quality products. Gating system guides and delivers the liquid metal flow from the mold entrance (pouring cup) to the product cavity. The purpose of gating system is to achieve better product quality by reducing casting defects, for example: shrinkage, incomplete filling, etc.

More Less

Product category: Investment casting

What is precision casting?

Precision casting (also called investment casting, lost-wax casting,and cire perdue) is a metal shaping technique to form near net-shaped products. The basic casting principle is to pour and to fill molten metal into a disposable ceramic mold. Then, the molten metal adapts to the shape of the mold and forms the final products. The technique has been around for thousands of years, as far as the bronze age. Even though it sounds like an old trick, but the research and development is still going up to this day. Even today, the casting foundries keep working to continuously improve the quality of casting products. Therefore, precision casting is one of the longest running advanced metal-shaping technology in human history. This article helps understanding: What is precision casting?

More Less

Product category: Investment casting

How does the process work?

The core process of precision casting are mold making and metal casting. In Zenith Allmart Precisindo, we recycle and reuse our waxes and excess metal parts during manufacturing. So, we always optimize our material loop within our foundry.

Mold making

  1. First, create wax patterns as models for the final products. Then, assemble the wax patterns to make wax pattern trees. Following this, assemble the wax pattern trees form metal delivery system and increase the casting efficiency.
  2. Next, dip the wax pattern trees into ceramic slurry, so ceramic shells coat the wax pattern trees. The ceramic shells adapt the shape of the wax pattern trees and form disposable ceramic molds. Later, dry the molds.
  3. Repeat the dipping to increase the thickness of ceramic shells because thicker shells provide higher mold strength. After the first layer, apply stucco to the ceramic shells.
  4. Remove the waxes from the molds (lost-wax). So, this de-waxing leaves negative cavities for later metal filling.
  5. Following de-waxing, fire the molds before the metal casting. Firing burns residual waste within the molds, sinters the molds,and pre-heats the molds for the subsequent metal casting.
Metal casting

  1. Melt metal above the melting temperature. Meanwhile, control and monitor the furnace temperature.
  2. If necessary, add alloying elements and slag-catchers to control the chemical composition of the molten metal.
  3. Pour the molten metal to fill the mold. Eventually, let the metal solidify. Also control cooling rate to control the micro-structure.
  4. After the cooling, break molds and cut excess parts. Finally, retrieve the metal as-cast product.
  5. Machining stage and finishing stage follow the metal casting to result in final product. Precision casting minimizes these stages because the as-cast product shape is already near net-shape of the final product. A succeeding article has been published about gating system of precision casting.

More Less

About us

Company details

ZENITH ALLMART PRECISINDO (ZAP) was established in 2006. Our core business is in metal subcontracting industry, especially for foundry investment casting or precision casting and subsequent machining process. We have been supplying our product to global industries such as: valve and pump; processing industry; power generation and energy sector; machinery industry; automotive and metal treatment industry; medical and rehabilitation; furniture and interior; building; vessel and weapon industry. Our customers spread all around the world, such as: Japan, Australia, Netherlands, Switzerland, Germany, Denmark, Sweden, and Indonesia.

In The Production Equipment area, company goal is to become a leader in the industry we are in, by investing in advance foundry machinery, foundry laboratory equipment, CNC machines both milling and turning, CMM and other supporting machinery that will help us to make products with high repeat-ability and reproducibility.

In The Business Process, we are aware that in subcontracting industry, reliability in quality; price; and delivery is not compromised. We are committed to always improving our value streams in our business process by implementing our knowledge in manufacturing system as well as the quality management system ISO-9001 : 2015. We emphasize more on “Continuous Improvement” because of all the products we produce are technically used (scrap). We guarantee our products are produced by the most excellence  manufacturing methods along with the state – of – the – art  machinery.

We would like to take this opportunity to invite the global industries for developing mutual and long term business relationship. ZAP wants to grow together with our customer as well as supplier.

ZENITH ALLMART PRECISINDO will be your most trustworthy  vendor for delivering quality product as per your requirements, on timely manner with competitive price to surpass your expectation.

More Less