Production Line
MES Electromechanical Casting Inc. was established in Esenyurt - Kıraç in 2002 to meet the needs of YILMAZ Group of Companies and the casting needs of our country and the world.
Yılmaz Redüktör A.Ş. and ELK Motor A.Ş. is included in the group and until 2014, the firm only acted within the framework of the needs of the group. With the new investments that started after 2007, a factory with an indoor area of 42.000 m2 in an outdoor area of 101.000 m2 was established in Tekirdağ Çerkezköy Organized Industrial Zone.
Mes Elektromekanik Döküm A.Ş, which makes gray-sphero and bronze casting, has a production capacity of 50.000 tons / year with ISO 9001-2015 quality certificate.
Inductotherm dual-track Induction Furnaces with a capacity of 6000 Kg / 2000 Kg / 1500 Kg / 500 Kg were installed in the Melting Section.
Künkel-Wagner has Sinto Automatic Molding Lines and Resin Molding Lines.
It has a daily production capacity of 40 tons of core with amine gas cold box core (8 units) and Shell shell core (3 units) processes.
Ductile Iron (Spheroidal Graphite Cast Iron)
Ductile iron grades produced in accordance with TSE 1563 (DIN EN1563) Standard:
Cast Iron (Lamella Graphite Cast Iron)
Cast iron qualities produced in accordance with TSE EN 1561 (DIN EN1561) Standard:
Bronze Casting
In accordance with DIN 1705 standard, thread die casting is made with G-CuSn12Ni alloy as bimetal in permanent mold.
The raw materials, which are approved by our own quality unit, are taken from our raw material stock area to the furnace charging loading trolleys with 2 magnetic cranes of 16 tons with digital display scale feature and the first step of the melting process begins.
The temperature and chemical analysis of the molten metal are controlled throughout the casting process to ensure compliance with quality standards and the specifications requested by our customers.
The metal forming journey continues in the molding line. MES Döküm has two automatic horizontal molding lines working with synthetic green sand and one resin molding line. Although the working principles of automatic molding lines are similar, they differ in terms of size and mold weight capacities. While the KÜNKEL WAGNER molding line enables the production of larger and heavier parts compared to the SINTO FBO III molding line, the resin molding line allows the production of high-weight and large-sized parts that cannot be cast in automatic molding lines.
Sand in the molding lines operating with synthetic green sand is in a continuous cycle. Sand rotating in molding lines is cooled in Simpson Sand Cooler and stored in silos. The sand of the quality required by the molding lines is mixed with bentonite, coal dust and water in automatic mixers in certain proportions and made ready for molding. The sand sent from the mixer to the molding machines sand reservoir is compressed under a certain pressure, allowing the model to take its negative shape.
Molding sand quality is very important for a quality casting and sand properties must be kept under constant control. The Hartley Device in the MES Casting sand preparation system keeps the sand going to the molding lines within the desired quality limits. The following features are continuously monitored with daily tests in the sand laboratory.
Sand Plant Equipment
KÜNKEL WAGNER SAND PREPARATION MIXER
4 Ton / batch - 90 Ton / hour sand preparation capacity
SINTO FBO II SAND PREPARATION MIXER
3 Ton / batch - 60 Ton / hour sand preparation capacity
SIMPSON SAND COOLER
100 tons / hour sand cooling capacity
HARTLEY SAND TESTER
Automatic adjustment of water and bentonite additions with compactness and wet compression strength measurement
Cores are placed in the mold in order to remove cavities and holes in the part. It is prepared from a mixture of sand and binder to show high mechanical properties and resistance to high temperatures, since it contacts with molten metal more than the other parts of the mold.
Core sand is obtained by mixing organic or inorganic binders and silica sand in a certain ratio. They are produced by gassing, firing or hardening as a result of the chemical reaction that occurs spontaneously over a period of time, after the desired form is given to the core sand with core boxes.
Core properties required for production;
Cores with these features are produced by using cold-box, shell and CO2 methods at MES Döküm.
LMA 60 lt.
LMA 25 lt.
PROTEK 40 lt.
PROTEK 25 lt.
FAZ 12 lt.
FAZ 10 lt.
BİLGE 25 lt.
ŞENER 15 lt.
ŞENER 10 lt.
Cores from 100 gr to 200 kg in weight are mass produced in the MES Casting core section.
The Cold-box system is mainly used in the core section. Waste amine gas absorbed from the machines operating in this system is precipitated in the amine gas washing unit, preventing harm to human health and nature.
Cores are produced using the CO2 method for jobs that are not suitable for machine sizes or for small quantities.
As a design, thin-section cores are produced with the shell method.
Special refractory paints are used to increase the resistance of the core surface against liquid metal. Refractory paints are applied to the core surface on a water and alcohol basis by dipping, washing or spraying technique. Cores painted with water-based paint are dried in a core drying oven.
In the sandblasting department, the sand castings coming from the molding lines shakers are cleaned by spraying steel balls. In addition, second sandblasting is done after grinding to remove the grinding marks and for visuality.
Sandblasting Machines
Grinding of the model separation surfaces, core joints, runners and feeder entrances of cast parts is done in this section.
Casting parts are primed in accordance with customer specifications. The primer paint application process is done by dipping and spraying.