Punjab-based DCM Engineering, the largest independent cylinder blocks and head foundry in India, has become the first Indian foundry to manufacture compacted graphite iron (CGI) castings using the Swedish SinterCast process control technology.
SinterCast is the world’s leading supplier of process control technology for high volume production of CGI. SinterCast produces a variety of CGI components ranging from 1.6kg to 17 tonnes, all using the same process control technology. End users of SinterCast-CGI components include Aston Martin, Audi, Caterpillar, Chrysler, Ford, General Electric Transportation Systems, General Motors, Hyundai, International Truck and Engine, Jaguar, Kia, Land Rover, MAN, MAN B&W Diesel, PSA Peugeot-Citroën, Rolls-Royce Power Engineering, Toyota, Volkswagen, Volvo and Waukesha Engine.
DCM's Ropar unit has an annual capacity of 72,000 tonnes of grey iron castings. The main products are cylinder blocks and heads delivered to leading Indian OEMs including Ashok Leyland, VECV, Mahindra & Mahindra, Tata Motors, Maruti Suzuki, General Motors, Hyundai, JCB and Perkins.
The company is now planning to set up a new foundry in Chennai with an annual capacity of 50,000 tonnes of castings to cater to its growing customer base in South India.
According to JK Menon, managing director, DCM Engineering, “We have delivered the SinterCast-CGI cylinder blocks weighing from 40 to 175kg after a two-week trial production lasting two weeks to passenger vehicle and commercial vehicle OEMs in the domestic market.”
The company believes there will be increased demand for CGI engine components as new road infrastructure and the forthcoming Bharat Stage IV emission norms will drive demand for improved engine performance.
Dr Steve Dawson, president and CEO of SinterCast, said: “We are delighted to have now completed our first casting trial with DCM Engineering. The foundry clearly demonstrated the ability to provide a high quality base iron and moulding medium for the successful production of CGI cylinder blocks. We look forward to continuing to work with DCM Engineering as we together support the CGI development needs of one of the world’s largest and fastest growing automotive markets.”