Our foundry
Welcome to WALKSON – a leading foundry factory dedicated to producing high-quality castings, including cast iron and steel castings, for a wide range of industrial applications. With a commitment to excellence and a focus on innovation, we provide precision-cast components tailored to meet the rigorous demands of modern industries, including automotive, machinery, mining, power generation, construction, and more.
Our state-of-the-art foundry facility is equipped with advanced technology and adheres to the highest industry standards to ensure every casting meets the required specifications. With a full range of capabilities from design to final production, we offer casting solutions that ensure the durability, strength, and performance needed for critical components used in harsh working conditions.
Our Capabilities:
1. High-Quality Cast Iron & Steel Castings
We specialize in producing both cast iron and steel castings that are known for their strength, durability, and ability to perform in extreme conditions. From gray iron and ductile iron to alloy steels and stainless steels, we provide casting solutions suited to your specific application needs. Whether your components require high wear resistance, corrosion resistance, or high-temperature performance, our foundry delivers high-quality, customized castings that meet industry demands.
2. Precision Machining
Our capabilities extend beyond casting to include finish machining. We offer a wide range of machining services, ensuring that castings are accurately processed to meet dimensional and functional specifications. With precision CNC machines, turning, milling, and drilling, we guarantee that every part is delivered with the necessary precision, surface finish, and tolerances required for optimal performance.
3. Non-Destructive Testing (NDT)
To ensure the highest quality standards, we implement a robust Non-Destructive Testing (NDT) process, including Magnetic Particle Testing (MT), Penetrant Testing (PT), Ultrasonic Testing (UT), and Radiographic Testing (RT). All NDT processes are performed in accordance with international standards such as ASME, DIN, and EN, ensuring that all castings are free from internal defects such as cracks, voids, and inclusions. This comprehensive testing guarantees the reliability and safety of every component before delivery.
4. International Standards Compliance
Our foundry strictly adheres to international quality standards such as ASME, DIN, and EN to ensure that our castings meet the highest performance and safety criteria. By using industry-standard methods and materials, we ensure that all products are of superior quality and fully compliant with global requirements.
5. Custom Solutions for Industrial Applications
Whether you need sand casting, investment casting, or die casting, we have the expertise and experience to meet your specific needs. We work closely with our clients to provide customized casting solutions, ensuring that each component is designed and manufactured to exact specifications. Our team of engineers and foundry specialists will work with you to solve even the most complex challenges.
Why Choose Us?
Expertise: With decades of experience in the casting industry, we are experts in producing high-quality castings tailored to industrial needs.
Advanced Technology: Our cutting-edge machinery and technology, coupled with a commitment to continuous improvement, ensure precision and consistency in every casting.
Quality Assurance: We pride ourselves on quality and adhere to stringent testing and inspection standards to ensure reliability and safety in every product we produce.
Customer-Centric Approach: We prioritize customer satisfaction, delivering high-quality products on time and providing ongoing support throughout the manufacturing process.
Global Reach: Serving industries worldwide, we are committed to providing solutions that meet both local and international requirements.
Industries We Serve
Our castings are used in critical applications across a range of industries, including:
Automotive: Engine components, suspension parts, gears, and housings.
Mining: Crusher parts, grinding mill liners, wear plates.
Power Generation: Turbine components, valves, pump parts.
Machinery & Equipment: Machine frames, gearboxes, industrial components.
Construction: Structural components, crane parts, rail components.
At WALKSON, we are committed to providing top-tier foundry services that combine technical expertise, high-quality materials, and innovative solutions for all your casting needs. Contact us today to learn more about how our precision castings and advanced testing can help improve the performance and longevity of your industrial components.
Welcome to WALKSON, a leading forging plant dedicated to producing high-quality forged components for a wide range of industrial applications. Specializing in both close-die forging and open-die forging, we manufacture a wide variety of components, including gears, shafts, and other custom forged products. Our products are renowned for their exceptional strength, precision, and durability, meeting the demanding requirements of industries such as automotive, aerospace, energy, mining, and manufacturing.
With cutting-edge equipment and an experienced team of engineers and technicians, our forging plant provides customized solutions to meet the specific needs of our customers. From DIN Level 5 gears to high-strength shafts and complex industrial components, we offer finish machining capabilities, professional heat treatment, and rigorous Non-Destructive Testing (NDT) to ensure the highest standards of quality and performance.
Our Capabilities
1. Close-Die Forging
Close-die forging is one of the most efficient methods for producing high-strength, high-precision components. At WALKSON, we utilize advanced closed-die forging techniques to produce parts that are tailored to meet exact specifications. This method is ideal for complex shapes and high-tolerance applications, delivering products with excellent mechanical properties and minimal post-processing requirements.
Applications:
1. Automotive Industry
Close-die forging is widely used in the automotive sector for manufacturing critical components that require high strength, durability, and precision. These forged parts are essential for ensuring the safety, performance, and longevity of vehicles.
Crankshafts: Forged crankshafts are essential for transferring the energy generated by the engine’s pistons to the drivetrain. Close-die forging allows for the creation of high-strength, fatigue-resistant crankshafts that can withstand the stresses of high-speed operation.
Connecting Rods: These components link the pistons to the crankshaft and must withstand high forces and pressures. Close-die forging ensures the rods have superior tensile strength and fatigue resistance.
Gear Blanks: Gear blanks for gearboxes, transmission systems, and differential components are often forged to provide the necessary strength and wear resistance.
Axles: Axles that drive a vehicle’s wheels must be robust and capable of handling the forces generated during driving. Forged axles offer superior strength, impact resistance, and fatigue resistance.
Steering Components: Components like steering knuckles, spindles, and shafts are forged to provide the necessary structural integrity for safe and responsive steering.
2. Aerospace Industry
The aerospace industry requires components that can operate under extreme conditions, such as high temperatures, stresses, and vibrations. Close-die forging is used to manufacture high-performance parts that meet the stringent requirements of the industry.
Turbine Blades: Forged turbine blades are crucial for aircraft engines. Close-die forging allows for the production of blades with excellent strength, resistance to fatigue, and heat resistance.
Landing Gear Components: Landing gear parts, such as struts, axles, and linkages, must be forged to withstand high impact forces during landings and take-offs.
Structural Components: Forged components like frames, brackets, and fasteners are used in the structural assembly of aircraft and spacecraft, where lightweight, high-strength materials are required.
Engine Components: Close-die forging is used for components such as compressor rotors, turbine discs, and shafts that are critical for the engine’s performance and reliability.
3. Oil and Gas Industry
The oil and gas industry operates in harsh environments, requiring components that can withstand extreme pressures, temperatures, and corrosive conditions. Close-die forging is often used for parts that must meet these demanding requirements.
Drill Bits: Forged drill bits are used in oil and gas exploration to penetrate tough rock formations. The high strength of forged steel ensures that the drill bits last longer and perform more effectively.
Flanges and Valve Bodies: Forged flanges and valve bodies are critical for ensuring leak-proof connections in piping systems. Close-die forging ensures these components can handle high-pressure and high-temperature environments.
Valve Components: Components such as valve bodies, valve stems, and seats must be forged to ensure durability and resistance to wear, corrosion, and high pressures.
Pump Components: Close-die forging is used to produce components like impellers, shafts, and pump housings, which need to be durable and resistant to both wear and corrosive fluids.
4. Heavy Machinery and Equipment
Heavy machinery and equipment used in construction, mining, and manufacturing industries rely on strong, durable components to handle high loads and harsh working conditions.
Crankshafts and Gearboxes: In large machines, forged crankshafts and gearboxes are used to transfer power efficiently. Close-die forging ensures these components are durable and can handle high stresses without failure.
Hydraulic Cylinders: Forged cylinder rods are used in hydraulic systems for lifting, pressing, and other heavy-duty operations. Close-die forging ensures that the rods have the necessary strength and resistance to fatigue.
Bearings and Shafts: Large forged shafts and bearings are crucial for supporting rotating parts in machinery, including presses, mills, and crushers. These components must resist bending, torsion, and wear.
Forged Rims and Housings: Large machinery often uses forged rims and housings for wheels, axles, and structural components that must withstand substantial forces during operation.
5. Energy and Power Generation
In the energy sector, particularly in power generation and renewable energy, close-die forging is used to manufacture parts that must withstand extreme conditions of pressure, temperature, and mechanical stress.
Turbine Parts: Components like turbine shafts, blades, and discs in power plants and wind turbines are often forged for superior strength, fatigue resistance, and durability.
Valve Seats: Valve seats in steam, gas, and hydroelectric power plants must be forged for high-temperature and high-pressure environments to ensure leak-tight operation.
Generator Rotors: Forged rotors are critical in generators for converting mechanical energy to electrical energy. The forging process ensures that the rotor is balanced, strong, and able to withstand centrifugal forces.
Heat Exchanger Components: Forged parts like flanges, tubes, and housings used in heat exchangers must be durable and resistant to corrosion under high heat.
6. Mining and Quarrying
Mining equipment and quarry machinery require components that can resist impact, wear, and abrasion, making forged components ideal for these applications.
Crusher Parts: Components like crusher hammers, jaws, and impact bars used in mining equipment are forged to withstand the severe impact and abrasive wear from crushing rock and ore.
Shovels and Excavator Parts: Forged components such as bucket teeth, pins, and arms are used in shovels and excavators, providing strength and resistance to wear in heavy-duty operations.
Drill Components: Forged drill rods, bits, and casings are used in drilling equipment for mining and exploration activities, ensuring performance and reliability under harsh conditions.
7. Rail and Transportation Industry
The rail industry relies on forged components for their durability, safety, and high load-bearing capabilities. Close-die forging is used in the production of various components that keep trains running smoothly and safely.
Train Wheels: Forged train wheels are designed to carry heavy loads, resist wear, and withstand the extreme stresses of rail transport. Close-die forging ensures the wheels are strong, durable, and capable of enduring long service life.
Axles and Bearings: Forged axles and bearings are essential for the functioning of railway vehicles. These parts must be forged to achieve high strength and resistance to fatigue and wear.
Railroad Couplings and Fittings: Components used in connecting trains, such as couplings and fittings, must be forged for strength and reliability to ensure safe operations.
8. Industrial Pumps and Compressors
Industrial pumps and compressors require forged components that can endure high-pressure conditions and resist wear and corrosion over long periods of operation.
Pump Casings and Impellers: Forged pump casings, impellers, and shafts are critical to ensure reliability and high efficiency in fluid and gas handling systems.
Compressor Rotors and Blades: Components such as rotors and blades in compressors are forged to handle high-speed rotation and ensure that systems operate with minimal wear.
2. Open-Die Forging
Our open-die forging capabilities allow us to produce larger and more robust components, typically used for heavy-duty applications where strength and durability are paramount. Open-die forging is ideal for producing flanges, rings, shafts, and other industrial parts with greater flexibility in terms of size and shape.
Applications:
Heavy machinery: Shafts, rollers, axles.
Oil & Gas: Flanges, valve bodies, drill rods.
Power Generation: Large turbine components, gears, and shafts.
3. Finish Machining
After forging, we provide precision finish machining to ensure that each part meets tight dimensional tolerances and functional requirements. Using state-of-the-art CNC machines, grinding, and milling, we ensure that forged components are accurately processed to meet customer specifications.
Applications:
DIN Level 5 Gears: Our plant specializes in producing DIN Level 5 gears with precision machining, which guarantees high accuracy and performance in gearboxes and other critical applications.
Shafts: Custom machined shafts for various industrial applications, including automotive, energy, and machinery sectors.
4. Professional Heat Treatment
At WALKSON, we understand the critical role that heat treatment plays in ensuring the optimal performance and longevity of forged components. Our professional heat treatment services are designed to enhance the mechanical properties of your forged parts, making them stronger, more durable, and resistant to wear, corrosion, and fatigue. Using the latest technology and techniques, we tailor heat treatment processes to meet the specific requirements of each application, ensuring the highest quality results.
Our heat treatment services are aligned with global standards, including ASME, DIN, EN, and ISO, and are backed by a team of experienced engineers and technicians dedicated to delivering superior results. We provide comprehensive heat treatment solutions for a wide range of industrial applications, including automotive, aerospace, energy, and heavy machinery.
Our Heat Treatment Services
1. Carbon Case Hardening (Carburizing) Carbon case hardening, or carburizing, is a heat treatment process used to harden the surface of steel components while maintaining a tough and ductile core. This process is ideal for components subjected to high wear and stress, such as gears, shafts, and bearings. The outer surface becomes hard and wear-resistant, while the inner core retains toughness and resistance to impact.
Applications:
Gears (e.g., automotive transmission gears, industrial gearboxes)
Shafts (e.g., drive shafts, crankshafts)
Bearings (e.g., roller bearings, needle bearings)
Benefits:
Increased wear resistance on the surface.
Retained toughness and flexibility in the core.
Improved fatigue strength.
2. Nitrogen Hardening (Nitriding) Nitrogen hardening or nitriding is a process where nitrogen is diffused into the surface of steel components, creating a hard, wear-resistant surface. This heat treatment method is often used for high-strength, high-durability parts, as it significantly enhances surface hardness and corrosion resistance. Nitrogen hardening is ideal for parts exposed to friction and harsh environments, such as gears, shafts, and valves.
Applications:
Gears (e.g., high-performance gears in automotive or aerospace industries)
Engine parts (e.g., camshafts, valve stems)
Hydraulic components (e.g., hydraulic cylinders, pistons)
Tooling and dies (e.g., dies used in metal forming)
Benefits:
Improved wear and corrosion resistance.
Increased surface hardness without compromising core toughness.
Enhanced fatigue strength and reliability.
3. Induction Hardening Induction hardening is a localized heat treatment process that uses induction heating to selectively heat the surface of a component. The part is then rapidly cooled (quenched), resulting in a hard surface with a tough interior. This technique is typically used for high-stress parts like shafts, gears, and crankshafts that need localized hardness in areas subject to wear or fatigue.
Applications:
Crankshafts and camshafts for automotive and industrial engines.
Gears (e.g., pinion gears, planetary gears in transmissions).
Shafts (e.g., driveshafts, axles).
Benefits:
Selective hardening, allowing targeted strengthening of high-stress areas.
High-speed process with minimal distortion.
Excellent wear and fatigue resistance.
4. Annealing Annealing is a heat treatment process that involves heating a material to a specific temperature and then slowly cooling it to relieve internal stresses, improve ductility, and refine the grain structure. This process is essential for materials that need to be easily machined or formed into complex shapes after forging. Annealed parts have better workability, reduced brittleness, and enhanced toughness.
Applications:
Shafts, rings, and discs that require enhanced machinability.
Forged components for aerospace, automotive, and heavy machinery industries.
Forging dies and molds used in manufacturing.
Benefits:
5. Quenching and Tempering Quenching and tempering is a two-step heat treatment process used to enhance the hardness, strength, and toughness of steel. During quenching, the component is heated to a high temperature and then rapidly cooled in a quenching medium (e.g., water or oil). In the tempering step, the component is reheated to a lower temperature to adjust its hardness and relieve internal stresses.
Applications:
Forged components in automotive (e.g., suspension parts, axles, gears) and heavy machinery (e.g., parts for mining and construction equipment).
Valve bodies and flanges for the oil & gas industry.
Fasteners and bolts used in high-stress environments.
Benefits:
Achieves a balance of hardness and toughness.
Improved strength and fatigue resistance.
Enhanced wear and impact resistance.
6. Stress Relieving Stress relieving is a heat treatment process that reduces internal stresses in forged components, which can result from the forging process or subsequent machining. By heating the material to a specific temperature and allowing it to cool slowly, this process improves the dimensional stability and reduces the risk of warping, cracking, or failure during service.
Applications:
Large forged components like machine frames and structural parts.
Heat-treated parts that have been hardened or quenched.
Tooling and dies that need to maintain dimensional accuracy.
Benefits:
Reduces residual stresses from forging or machining.
Improves dimensional stability and reduces the likelihood of distortion.
Increases the material’s ability to withstand future stress and load.
7. Vacuum Heat Treatment Vacuum heat treatment is a specialized process that takes place in a vacuum chamber to prevent oxidation and contamination of the material. This process is particularly beneficial for high-value or sensitive parts where surface cleanliness and uniformity are crucial, such as aerospace components, medical devices, and high-precision tooling.
Applications:
Aerospace parts (e.g., turbine components, critical fasteners).
Medical devices (e.g., surgical tools, implants).
High-precision components (e.g., gears, shafts, and dies).
Benefits:
Elimination of oxidation and contamination.
Enhanced surface finish and cleanliness.
Improved material properties with high precision.
Why Choose Our Heat Treatment Services?
State-of-the-Art Equipment: Our forging plant is equipped with the latest heat treatment technologies, ensuring that each component is processed with precision and efficiency.
Customized Solutions: We offer tailored heat treatment services based on the specific requirements of each forged part, ensuring that the material properties are optimized for performance.
Expert Team: Our team of engineers and heat treatment specialists work closely with clients to determine the best heat treatment processes for each application.
Quality Assurance: Every heat-treated part is rigorously inspected and tested to ensure it meets stringent industry standards such as ASME, DIN, EN, and ISO.
Global Compliance: Our heat treatment services comply with international standards to ensure that your components perform reliably in the most demanding applications.
Comprehensive Testing: We offer full Non-Destructive Testing (NDT) services (MT, PT, UT, RT) to ensure the integrity and quality of heat-treated components.
5. Non-Destructive Testing (NDT)
Ensuring the quality and reliability of forged products is a key priority. To meet international standards, we implement comprehensive Non-Destructive Testing (NDT), including:
Magnetic Particle Testing (MT): For detecting surface and near-surface defects in ferromagnetic materials.
Penetrant Testing (PT): For detecting surface-breaking defects in non-ferromagnetic materials.
Ultrasonic Testing (UT): For detecting internal flaws and ensuring material integrity.
Radiographic Testing (RT): For detecting internal and surface defects using X-rays or gamma rays.
All NDT procedures are performed in compliance with international standards such as ASME, DIN, and EN, ensuring that all forged products meet the highest standards for safety, reliability, and performance.
Why Choose Us?
Advanced Forging Technology: Our forging plant is equipped with the latest forging equipment and technology, enabling us to produce both close-die and open-die forged products with precision and consistency.
Custom Forged Solutions: We work closely with our clients to develop customized forging solutions that meet specific design and performance requirements.
High Precision and Tolerances: Whether it's DIN Level 5 gears or complex shafts, we guarantee precise tolerances and excellent mechanical properties, ensuring the highest quality of finished products.
Heat Treatment Expertise: Our professional heat treatment processes ensure that every forged component has the ideal balance of hardness, toughness, and wear resistance.
Comprehensive Testing: Our NDT services, including MT, PT, UT, and RT, provide assurance that all products are free from defects and meet stringent quality standards.
International Standards Compliance: Our plant strictly adheres to the highest global standards, including ASME, DIN, and EN, ensuring that every product meets both customer expectations and regulatory requirements.
Industries We Serve
Our forging plant produces critical components for a wide range of industries, including:
Automotive: Crankshafts, gears, axles, and engine parts.
Aerospace: High-strength forged components for engines, turbines, and structural parts.
Energy: Turbine shafts, valve bodies, pump parts, and other power generation components.
Mining: Heavy-duty forged parts like gears, shafts, and mill liners.
Oil & Gas: Flanges, valve bodies, drill rods, and other heavy-duty components.
Construction: Forged components for machinery, heavy equipment, and structural applications.
Conclusion
At WALKSON, we are committed to providing high-quality close-die and open-die forged products that meet the toughest industrial standards. Our advanced capabilities in forging, precision machining, heat treatment, and Non-Destructive Testing (NDT) ensure that each component meets or exceeds industry requirements for performance, reliability, and safety.
Whether you need DIN Level 5 gears, high-strength shafts, or other precision forged components, we offer tailored solutions that deliver long-lasting and cost-effective results. Contact us today to learn more about how our forging capabilities can support your industrial needs.
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