EMC LIMITED

FORGING AHEAD WITH EXPERIENCE

FORGING AHEAD WITH EXPERIENCE FORGING AHEAD WITH EXPERIENCE

EMC LIMITED is a leading power system company in India offering a

total turnkey solution in the field of Transmission line projects upto 800KV,

EHV Substation and power distribution projects. The Company also offers

complete turnkey solutions for setting up Tele-communication systems.

Apart from Tower manufacturing and Transmission line construction and

erection, EMC has two factories in Kolkata producing high quality

conductors, non-ferrous extrusions and forgings for sophisticated

applications.

In the field of Aluminium alloy forgings, EMC has developed and supplied

several critical products for Defence, Electrical, Engineering, Locomotive

and Automobile industries. The company specializes in high strength

Aluminium alloy forging. EMC produces aluminium alloy extruded rod, bar

and flat in heat treatable alloys.

EMC is forged and extruded products come with a complete assurance of

quality. From the selection of raw material the process parameters are kept

under close control. The company’s R&D wing is continuously working on product innovation and design optimization. Product quality is ensured

through stage inspection and testing by the dedicated Quality Control

Department supported by a well equipped chemical laboratory in pursuance

with the company’s quality policy and customer’s specific requirement.

EMC has its own alloy making and billet casting units. Post extrusion

operations such as heat treatment is done in-house. Press and hammer

forging are done for Aluminium alloys. The manufacturing facilities include

pneumatic hammers, friction screw press, drop hammers, electrically

operated furnaces for production and heat treatment, homogenizing

furnace, extrusion press, rotary melting furnace and DC Caster.

ALUMINIUM ALLOY EXTRUSION

EMC LTD. is among pioneers in India producing heat treatable hard alloys in solid

form like rods, bars and flat for over 3 decades. Typical alloys are in BS-6000,

2000 & 7000 series. Alloy billets for extrusion are cast in-house through Direct

Chill Casting method under strict quality control norms. Composition of each cast

lot is checked in a state of the art Spectrometer.

FORGINGS

Aluminium extruded rods/bars cut to length form the forging stock. Forging is

done in Drop Hammers & Mechanical Presses. Best forging practice is followed to

obtain quality components.

1.5 T Drop Hammer

Steel forging is done in Drop Hammers. Steel rounds/bars sourced from reputed

Steel Mills are cut to length and used as forging stock.

HEAT TREATMENT

To achieve desired mechanical properties and grain structures Aluminium

extrusions/forgings are subjected to heat treatment (Solution & Ageing) in electric

furnaces under precise control.

Solution Heat Treatment

Normalizing treatment of Steel Forging is done in electric furnace with chart recorder.

INSPECTION & QUALITY ASSURANCE

Aluminium forgings/extrusions are subjected to 100% ultrasonic testing to detect

internal cracks. Visual inspection of each component is carried out. Hardness

check and Mechanical test is done for each production batch.

Crack detection test of every steel forging is done in MPI along with visual

inspection. Micro structure is checked in Optical Microscope and digitally recorded

to generate test reports.

For Automobile Industry

Connecting rods, kick paddle, tank piston,

V Belt pulley, cam gear, fork, crown

bottom, GP bush some of the major

components manufactured by the

company

For Switchgear Industry

Ansculus, outer and inner galenk, cam,

contact drive case, pilot support to

mention a few.

Product parts for Defense Sector

Body cover, spider, adopter nut, base

adopter, trigger brackets, trigger guard,

cartridge case, kousing, tail unit and

bridge valve housing, lower body with

fin

EMC extrusion and casting products come with a complete assurance of quality. This is achieved as a result of untiring attention and meticulous process control at

every stage of manufacturing. EMC has its own alloy making and billet casting units. Aluminium extrusions in a

variety of shapes are produced in high duty and special grade alloys. Post extrusion operation such as stretching and heat treatment in it’s own integrated plant. Press and hammer forging are made in aluminium and copper based alloys. The manufacturing facilities include pneumatic hammers, friction screw presses, drop hammers, electrically operated furnaces for production and heat treatment.

EMC specializes in high strength aluminium and high conductivity alloy forging.

EXTRUSION

FORGING

MELTING CASTING CUTTING HOMOGENISING EXTRUSION

STRETCHING CUTTING HEAT TREATMENT PACKING DESPATCH

MATERIAL CUTTING SOAKING LUBRICATION FORGING

TRIMMING DEBURRING HEAT TREATMENT MACHINING PACKING

DESPATCH

SPECS OF MAJOR ALLOYS (FORGED)

Alloy Condition Uts

Kg/mm2 Yield

Kg/mm2

Elongation

(%) Min.

Typical applications

2014 HE - 15

WP W

45 38

39 23

6 10

Components like Connecting Rods, Pedal

Levers, Kick Starters, Handle Holders, Cap

Forging etc.

63400 WP 19

16 7 Windows frame and

architectural use

65032 WP 29 24 7 Structural applications and Electrical Switch

Gear and Extrusions

HE 12 (RR 56)

WP 40 30 6 Automotive applications, Extrusions etc.

24534 WP 38 23 8 Aircraft Parts and Structurals

6351 HE-30

WP W

30 19

26 12

7 14

Projectile Body

GOST B-95 WP 56 44 4 Defence Applications

DTD 5124 (AW-7075)

WP 56 50 4 Frame for Revolvers, AFT Closure, Plunger,

Minnacle Ring, Connecting Lever

Forgings

2258 WP 38 27 - Automobile Piston, Cylinder Heads, Aircraft

Forgings, etc.

DTD 5024 WP 51 44 6 Fin Body

Aluminium Alloy Compositions

Sl IS:733 EN:255 % Cu % Mn % Mg % Si % Zn % Cr % Ni % Fe

1

24345

(HE15)

2014 3.8-1.2 0.2-0.8 0.5-1.2

2

63400

0.4-0.9 0.3-0.7

3 65032

0.15-0.4 0.2-0.8

0.7-1.2 0.2-0.8 0.15-0.35

4 64430

(HE30)

6082 0.4-1.0 0.4-1.2 0.6-1.3

5 HE12

1.8-2.8 0.6-1.2 0.5-1.3 0.6-1.4 0.6-1.2

6 24534

3.5-4.7 0.4-1.2 0.4-1.2 0.2-0.7

7 GOST

B95

1.4-2.0 0.2-0.5 1.8-2.8 <0.5 5.0-7.0 0.1-0.25 <0.5

8 22588

1.8-2.7 1.2-1.6 <1.3 0.6-1.2

9 DTD

5124

7075 1.2-2.0 2.1-2.9 <0.4 5.1-6.4 0.1-0.25

10 DTD

5094

0.3-0.7 0.3-0.7 2.2-3.2 <0.5 5.2-6.2

Non Ferrous extrusion

and forgings for

sophisticated

applications

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