Quality Assurance
Quality assurance at “Ishaan Forgings India” is our unwavering commitment to ensuring that our forged components meet the highest quality, safety, and durability standards. We adhere to stringent industry-specific quality certifications, maintain comprehensive testing and process control measures, document our processes meticulously, and prioritize employee training. Our focus on continuous improvement ensures that our components consistently meet or exceed customer and regulatory requirements, reinforcing our reputation for delivering reliable and high-quality forged products.
Non-Destructive Examination
Ultrasonic Examination:
In the forging industry, ultrasonic testing is a cornerstone of quality control. This non-destructive testing method employs high-frequency sound waves to detect internal defects, irregularities, and inconsistencies within forged components. By sending ultrasonic waves through the material and analyzing their reflections, ultrasonic testing ensures that the final forged products meet stringent quality standards. It plays a crucial role in verifying the structural integrity of components, identifying hidden flaws, and upholding the safety and performance of forged materials in various industrial applications. This technology is a trusted ally in forging industries, where precision and reliability are paramount.
Magnetic Particle Examination:
Magnetic particle testing is a vital quality control method employed in the forging industry. It detects surface and near-surface defects in ferrous materials by applying magnetic fields and magnetic particles to the component’s surface. This process reveals cracks, fissures, and other imperfections that might otherwise go unnoticed. In forging, where safety and integrity are paramount, magnetic particle testing ensures that components are free from flaws, ensuring their reliability and durability in various industrial applications. This method is a cornerstone of quality assurance, guaranteeing that forged products meet the highest standards of excellence.
Liqiud Penetrant Examination:
Liquid penetrant testing is a vital quality control method in the forging industry. This non-destructive testing process involves applying a liquid penetrant to the surface of components, allowing it to seep into any surface-breaking defects. After a specified dwell time, excess penetrant is removed, and a developer is applied to bring out and visualize the defects. This technique is invaluable for identifying fine surface cracks, porosity, and other imperfections in forged components, ensuring their integrity and reliability. Liquid penetrant testing plays a crucial role in maintaining the high-quality standards and safety of forged products used in diverse industrial applications.
Mechanical Testing:
Destructive testing, including methods like Tensile, Hardness, and Impact Testing, is a critical component of quality assurance in the forging industry. These tests, carried out in strict adherence to national and international specifications and standards, involve the physical alteration or damage of test specimens to assess the mechanical properties, strength, and durability of forged components. Tensile tests determine a material’s strength and elasticity, hardness tests evaluate its resistance to deformation, and impact tests gauge its ability to withstand sudden shocks. By subjecting samples to these tests, we gain valuable insights into the performance and safety of forged products, ensuring they meet the rigorous quality standards demanded by various industries. Destructive testing plays a pivotal role in forging’s commitment to delivering robust, reliable, and safe components.
Final Inspection and PMI:
The final inspection and dimensional analysis of forged parts represent the culmination of a meticulous quality control process in forging manufacturing. At this crucial stage, each component is subject to rigorous scrutiny, ensuring that it adheres to the exact specifications and tolerances stipulated by national and international standards. Dimensional analysis verifies critical measurements, geometries, and tolerances, guaranteeing that the forged parts are precise and ready for integration into their intended applications. This meticulous process provides the ultimate assurance that the components meet the highest quality standards, offering dependability and safety in a wide range of industrial sectors, from oil and gas to automotive. It is the crowning step in our commitment to delivering excellence in forged components.
Conducting Positive Material Identification (PMI) during the final inspection of forged products is a crucial quality control measure. This process helps confirm that the materials used in the forged components match the specified alloy or grade, ensuring that the final products meet the required quality standards and safety criteria. PMI at this stage provides an additional layer of assurance, safeguarding against material mix-ups and enhancing the overall reliability and integrity of the forged products.
Packaging, Rust Prevention, and Wooden Box Protection for Forged Products:
Our commitment to safeguarding your forged products extends to a comprehensive packaging approach. For components that require the utmost care and protection, we employ a combination of methods to ensure their safe transit.
First and foremost, we employ wooden boxes as sturdy and protective encasements for your forged components. These wooden boxes are designed to withstand handling, stacking, and the rigors of transportation, ensuring that your components remain secure and intact.
Within these wooden boxes, we insert corrugated sheets, acting as an additional layer of protection. These sheets are strategically placed to separate and cushion the forged products, preventing any potential contact and ensuring that they reach their destination without any unintended impacts or damage.
Moreover, to guard against corrosion, we apply rust-preventive coatings to the components before placing them within the wooden boxes. These coatings create a barrier against moisture and oxidation, preserving the quality of your forged components during storage and transit.
Whether your components require aesthetic considerations, protection against harsh environmental conditions, or simply the assurance of safe handling, our packaging, rust prevention, and wooden box protection measures collectively guarantee the arrival of your forged products in optimal condition. We understand that the integrity of your components is paramount, and our commitment to quality encompasses every aspect of our service, from forging to final delivery.
Certifications (ISO 9001:2015):
Being an ISO 9001:2015 certified forging company reflects our unwavering dedication to quality and excellence. This internationally recognized certification underscores our commitment to maintaining the highest standards of quality management throughout our operations. We adhere to the stringent requirements and guidelines set forth by ISO 9001:2015, ensuring that every stage of our forging process, from material selection to final inspection, is meticulously controlled and documented. Our ISO certification serves as a testament to our ability to consistently deliver forged products that meet or exceed industry standards and customer expectations. It is a symbol of our commitment to quality and a reflection of our continuous efforts to enhance our processes and exceed your forging needs.
Metallurgist:
A metallurgist with eight years of research and development experience is an invaluable asset to our forging company. Their expertise in material selection, process optimization, and quality control ensures that our forged components meet the highest standards of quality and performance. Additionally, their research and development skills drive innovation, helping us stay competitive and at the forefront of technological advancements in the forging industry. Their problem-solving abilities are instrumental in addressing any challenges that may arise, ultimately contributing to our commitment to delivering reliable and innovative forged products to our customers.
ASNT NDT level-3:
Having a highly experienced ASNT NDT Level-3 expert for non-destructive testing is a cornerstone of our commitment to quality and safety. ASNT (American Society for Non-destructive Testing) Level-3 certification represents the highest level of competence in NDT and ensures that our testing processes are conducted with the utmost expertise and precision.
With this level of proficiency, our ASNT NDT Level-3 expert plays a critical role in setting NDT procedures, interpreting results, and training and certifying our NDT personnel. Their experience and knowledge are instrumental in maintaining the reliability and integrity of our forged products. We can confidently guarantee that our NDT practices are executed with the highest standards, offering dependable and safe forged components to our valued customers.
⦁ Products:
Product Grades and Specifications:
Carbon Steel: Our forging capabilities include various grades of carbon steel, meeting industry standards and customer-specific requirements.
Grade: A105, SA266, LF2, LF3, EN8, EN9, F42, F52, F60, F65, F75, and more
Alloy Steel & Micro alloy: We offer a range of low and high alloy steel options, providing strength and corrosion resistance as needed.
Grade : EN19, EN24, EN25, EN26, 4130, 4340, 4140, 8620, 8630, F1, F5, F9, F11, F22, F91, F6NM, 42CrMo4, 16Mo3, 25CrMo4, 30CrNiMo8,
Stainless Steel: Our Stainless Steel forgings adhere to international specifications, ensuring durability and corrosion resistance.
ASTM : 304/304L, SS-310, 316/316L, 316Ti, 321, 304H, 316H, 317L, 347, 347H, 904L and more
EN : 1.4307, 1.4404, 1.4571, 1.4541, 1.4401, 1.4432 and more
Duplex Stainless Steel: We specialize in producing forgings from duplex stainless steel, known for its exceptional strength and corrosion resistance.
Grade: F51 / F60 (2205), 1.4462, F53 (2507), 1.4410, F55, F44
Nickel Alloys: Our expertise extends to nickel alloys, meeting demanding specifications for high-temperature and corrosive environments.
Grade: 600, 625, 800 H/HT, 825, Alloy 20, Alloy22, Alloy 400 and 500 and Alloys Alloy C276
- Product Size Range:
Our forging capabilities encompass a versatile size range to cater to various customer needs:
Flanges (½” to 60”): We offer a range of flange sizes, from small to large, accommodating diverse industrial applications.
Rings: Our forging expertise extends to rings of various diameters and thicknesses, designed for structural and mechanical applications.
Tube Sheets: We provide tube sheets in different dimensions, meeting the precise requirements of heat exchanger and pressure vessel applications.
Shafts: Our forging capabilities include shafts of varying lengths and diameters, suited for applications in machinery and equipment.
Customized Forgings: We excel in producing tailor-made forgings to match unique specifications, ensuring our products meet the specific needs of our customers.
Standards : Types
ASME/ANSI B16.5 : Welding Neck Flange, Slipon Flange, Blind Flange, High Hub Blind Flange,
Socket Weld, Flange, Lap Joint Flange, Threaded Flange, Long Weld-neck Flange
Pressure Class : 150, 300, 400, 600, 900, 1500, 2500
ASME/ANSI B16.47 : Welding Neck Flange, Blind Flange (Series A & B)
Pressure Class : 150, 300, 400, 600, 900
ASME/ANSI B16.36 : (Orifice Flanges) Welding Neck Flange, Slipon Flange, Threaded Flange
Pressure Class : 300, 400, 600, 900, 1500, 2500
ASME/ANSI B16.9/ : Stub End
MSS SP-43 Size Range: 1/2” to 24”
DIN Flanges/ : DIN2527, DIN2566, DIN2573, DIN2576, DIN2641, DIN2642, DIN2655, DIN2656, DIN2627,
EN 1092 – 1 DIN2628, DIN2629, DIN2631, DIN2632, DIN2633, DIN2634, DIN2635, DIN2636, DIN2637,
DIN2638, DIN2673
ASME/ANSI B16.48 : Figure 8 – Spectacle Blind
AWWA – C 207 : Slip on Flange, Blind Flange, Ring
Forged Bars : 8” to 32” (200 mm to 800 mm)
Custom Forgings : As Per the requirement.
This comprehensive range of product grades, specifications, and size options demonstrates our commitment to meeting diverse industry demands and delivering high-quality forged components.