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Engineering Design & Simulation

Our Engineering team provide access to multiple seats of integrated CAD & Magmasoft simulation software. This allows us to support our customers with design appraisal, tooling design and foundry method designed to exceed our customer expectations.

Magma® 5 computer simulation and flow analysis, combined with the knowledge and experience of our engineering personnel, allows us to optimise casting methods and work towards a dedicated ‘right first time’ approach.

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Tooling Manufacture & 3D Design

Our in-house pattern manufacturing facility works concurrently with our engineering team, producing patterns to an extremely high standard. Utilisation of CADCAM alongside traditional techniques allow us to adapt our production technique to ensure timely delivery of patterns to the sand foundry. Investment casting is a key part of our foundry strategy and therefore so is injection tooling. Injection tooling design and manufacture is supported through sub-contract partners and internal manufacture.

We also appreciate that patterns and tooling aren’t for everyone! Our integrated 3D technologies through our partnered suppliers, such as Voxeljet, allow us to support rapid prototyping, pre-tooling development and small run production without the need for fixed tooling or patterns.

3D printing technologies are available both for investment and sand casting through the use of Wax & Plastic for Investment casting and 3D printed sand. 3D Printed sand utilising compatible binder technology allows for us to manufacture parts without tooling but also without the restrictions of traditional moulding methods.


Sand and Investment Casting

The interchangeability between our four furnace stations allows us to be flexible with our melting capacity to suit varying customer requirements and demand. From smaller production runs to larger project support, our specialised silicate sand foundry and investment casting process can support small near nett shape castings through to large 1400kg sand cast components.

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Heat Treatment & Full Material Testing

With four heat treatment furnaces, fully calibrated at varying temperatures from 600°C – 1250°C allow for complete and accurate heat treatment of all our cast grade alloys. The process offers full traceability including certification, meeting standards such as ASTM A991 and Norsok Approval.

Through the utilisation of third party ISO 17025 approved Laboratories and our internal metallurgical lab, we offer a full scope of material testing for all cast grade alloys. From corrosion testing through to microstructure analysis our facility or network of suppliers can accommodate our ever-expanding customer demands on material testing.


Welding & Fabrication

Working to ASME IX and equivalent standards, our welding department is fully approved to weld all of our materials in continued production. Supporting customers with full fabrication welds, overlay Hardfacing and repair welding. Our diversely qualified welders are trained to the highest of standards utilising both GTAW & SMAW techniques.

Many of our weld procedures have been subjected to third party review and approval such as Norsok and IBR (Indian Boiler Regulations).

Machining

Our highly equipped machine shop is optimised and developed to support the machining of the cast materials for which we specialise. We maintain a full range of manual machine tools alongside heavy-duty CNC machining centres, this allows us to support our customers with one-off and prototype production, alongside larger project support.

Integrated CADCAM technology and networked cells of machine tools allow us to find the balance between productivity, competitiveness & speed. Complex fixturing, and tooling allow us to utilise lights-out hours of production giving us extra capacity when we need it.

We don’t cast everything which we machine! We also support global customers with forging and bar procurement and machining thereafter.

NDE & Quality Assurance

We work closely with our suppliers to ensure that quality of product and service remains at the very highest level, which we have come to expect and so have our customers. We offer a complete range of in-house and outsourced non-destructive testing techniques.

Liquid Penetrant Inspection

Full on-site LPI facilities for detecting surface-breaking discontinuities in all non-porous material. All technicians are qualified in accordance with both SNT-TC-1A and ISO 9712. This process can be performed in accordance with ASME V, ASTM E165 and/or European equivalents, and can also be tailored to customer requirements with separate procedures being written and approved by our onsite Level III (SNT-TC-1A).

Magnetic Particle Inspection

For ferromagnetic materials we can offer Wet-Fluorescent Magnetic Particle Testing detecting surface-breaking and slightly subsurface discontinuities in accordance with requirements. All technicians are qualified in accordance with both SNT-TC-1A and ISO 9712.

Radiography & Ultrasonic Testing

Brafe operates with partnered testing houses, such as Aerotech NDT, to provide Radiography and Ultrasonic Testing to customer requirements. The utilisation of a broad scope of RT technology including Betatron, Iridium 192 & Cobalt 60 allows us to shoot up to 8” thick steel sections and select the right process for the right product.

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