Adaptor Kit  Listing Guide
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FABRICATED PRODUCTS:
Equipped with comprehensive fabrication machinery, this section is responsible for production of kits in fabricated and welded steel. This allows for low to medium volume production and short lead time projects.

CAST PRODUCTS:
This section produces brackets and kits in cast aluminium, with all components heat treated to T6 temper for maximum strength . It includes two tilting permanent mold (gravity die) casting machines, fed by a 500kg capacity melt/hold crucible. The molten metal temperature is automatically controlled to +/- 5 degrees C.  Both machines feature variable control of tilt rate, solidification timing and eject stroke. They are also equipped with automatic core pull mechanisms. Complementing these operations are shell core production and heat treatment processes.
The casting facility has a  production capacity in excess of 300 castings per shift.

DESIGN, DIE PRODUCTION AND MACHINING:
Casting and Die designs are generated  as 3D models ,  utilizing  Hewlett Packard “Solid Designer” CAD software. These designs are transferred to toolpaths by a “hyperFORM” CAM package.  Machining of both dies and components is carried out on a Mazak VTC 20  Vertical Machining Centre.

CASTING QUALITY CONTROL:
The “traceability” of cast aluminium  components and constant quality are regarded as imperative and are ensured by the following processes.

 Only virgin Comalco alloy is used, and all components are produced in AC603, (US A357) This high tensile strength alloy also is commonly used in aviation components such as helicopter rotor hubs.

 Each material batch is delivered with a “batch report” and a “Certificate of Analysis”. This analysis is compared to the correct material spec and if the material conforms it is “logged in to stock”.

  With each casting run, die inserts are date coded, which also identify consecutive days within that casting run. “Run sheets” record any variance in shot procedures and alterations to die coatings, etc. during the run. 

 Before heat treatment, the heat treat process sheet indicates:

1.  Material batch no.

2.  Casting run no.

3.  Casting date.

 Heat Treatment process analysis is recorded against the batch and run number, and “test pieces” from the casting melt are also heat treated with the “casting batch”. Mechanical analysis is then performed on these test pieces.

This procedure ensures that from the date code on any casting, we can determine:

(A) The material details; both batch # and chemical analysis.

(B) The date the casting was produced.

(C) Melt and die temperatures for the casting run.

(D) The heat treatment process details.

(E) The physical properties of the material used in the casting     batch in terms of

1. Ultimate tensile strength.

2. Yield strength.

3. Elongation.

4. Hardness (Hb).

This process ensures 100% traceability of any casting.