• castings producer
    made of aluminum alloys
    in sand and metal mould forms
  • we invite you to cooperation

About us

Instytut Wdrożeń i Technologii Sp. z o.o. is a foundry producing castings made of aluminum alloys in gravity technology in sand and metal mould forms, having its own numerically controlled CNC machine park (milling machines, lathes) located in Starachowice (Świętokrzyskie district), Poland. 

 

The company also specializes in execution of castings tooling and offers for aluminum castings additional on-site services in the form of machining on numerically controlled CNC machines (milling machines, lathes), heat treatment (T1, T4, T5, T6, T64, T7), sandblasting, leak testing.  

 

As part of external cooperation, we additionally offer services such as surface treatment of aluminum castings (e.g. anodizing, phosphatizing, chromating, powder and wet painting) as well as penetration and X-ray tests.

 

The aluminum foundry was founded in 1999 and bases its statutory activity on the potential and intellectual resources acquired at Odlewnie Polskie S.A. In 2005, shares in Instytut Wdrożeń i Technologii Sp. z o.o. were purchased from Odlewnie Polskie S.A. by two private persons; currently the only partner of the company is Zbigniew Dutkiewicz.

 

The company has invaluable experience related to the implementation and use of the ISO 9001:2000 certificate issued on October 4, 2005, which confirms the introduction and application of a quality management system in the design and manufacture of foundry equipment and the production of castings and their machining.

 

One of the company's main tasks is to implement new technologies; the company has experience in slimming production costs supported by replacing the process of machining aluminum details from rolled profiles to the machining of casted parts.

 

The company's services are currently used by international companies from the following sectors:

  • rail industry - France and Belgium;
  • shipbuilding industry - Poland, Germany;
  • automotive industry - Germany, Sweden;
  • defense industry - Poland, England, Belarus;
  • energy industry - Poland;
  • aviation industry - France
     

Most of inquiries are being processed within several days meanwhile we believe in production of aluminum castings based on Just-In-Time delivery concept.

Designing

To design aluminum castings we use the following software: CAD (Pro/ ENGINEER, PTC CREO Parametric 3.0, Unigraphics NX 12.0). We use CAM software (Pro/ ENGINEER, PTC CREO Parametric 3.0, Unigraphics NX 12.0 and EdgeCAM), 2D flat documentation (paper and electronic) and 3D solids received from our clients to manufacture models, molds, core boxes and CNC machining of castings. It is possible to import projects to the program supported by our technologists Pro/ ENGINEER, PTC CREO Parametric 3.0, Unigraphics NX 12.0 from external programs in all formats, including: STP; IGS; PAR; PARASOLID, CAT; VDA; STL.

 

We also use the ProCAST program for computer simulation of casting pouring and solidification processes, which allows you to simulate:

 

  • Gravity, centrifugal, high and low pressure casting, full form technology, etc.
  • Casting for mobile and fixed ceramic and solid forms.
  • Liquid-solid (thixotropic) casting.
  • Semi-continuous and continuous casting.
     

Files generated in CAD software are imported by CAM software supporting production, which then generates "NC" codes for the needs of CNC machines.

 

 

Picture #1. Casting design of aluminum alloy developed at Instytut Wdrożeń i Technologii Sp. z o.o.

 

The gray casting presented on picture is made on metal mould casting line. The upper and lower mold - green - reflects the external shapes of the casting. Before assembling the mold, a sand core is placed inside - brown colour. The core was made in NO BAKE technology from a self-hardening mass in a core box made of resin model plates. This production technology ensures both high casting tolerances and its strength parameters.

Pattern Shop

Pattern shop is highly specialized and modern department with long lasting experience which offer the following services:

 

  •  Execution of foundry tooling, models, moulds and core boxes from steel, aluminium and non- ferrous metals
  • Moulds from grey and spheroidal iron
  • Negatives of models and prototype tooling from resin
  • Assembly of models on the plates, the set of models and final machining of core boxes
  • Adaptation of models' set between various casting technologies
  • Execution of 3D models in Pro/ENGINEER software
  • Execution of tools' paths for machining of models on CNC machines
  • Implementing of technology allowance such as: rake of the walls, machining allowance and casting shrinkage
  • Machining in Pro/ENGINEER software 
  • Generation of 3D solids of models and core boxes basing on model of the casting
  • Generation of tool's paths in EDGECAM software for purposes of CNC AVIA VMC 650 machine 

 

The models and their negatives are being executed on vertical machining centre AVIA VMC 650.

The maximum dimensions of milled models are: X/Y/Z 650/540/620.

Maximum burden is 620 kg.

 

 

Picture #2. Casting design of aluminum alloy with the best strength properties Rm = 400 MPa; HBW ≥ 110 according to EN 1706: 2010 executed at Instytut Wdrożeń i Technologii Sp. z o.o.

 

This material can be used in many industries to replace other castings, including iron. Casting made on the metal mould line is marked in gray colour. The upper and lower mold - green - reflects the external shapes of the casting. To make one casting, 10 sand cores - yellow - executed in NO BAKE technology, are being placed inside the mold. Cores are made on a flaskless molding line with core boxes made of resin model plates. Then the cores are placed symmetrically on the right and left sides of the mold. The mold prepared in this way is poured with appropriately prepared metal with strictly maintained temperature parameters as well as a suitably selected chemical composition, so as to ensure all the required quality parameters of the product.

Aluminium Foundry

We specialize in production of complicated high-series as well as low-series aluminum castings made in sand, metal mould and mixed technologies.

 

We perform precipitation strengthening for the following aluminum alloys: AlSi7Mg0,3; AlSi7Mg0,6; AlSi9Mg; AlSi10Mg, AlCu5MgMn, AlCu4Ti; Alsi4MgTi; AlZn10Si8Mg; this treatment increases the strength properties of castings by 100%, thanks to which we obtain Rm above 400 MPa.

 

The thinness of the walls made by Instytut Wdrożeń i Technologii Sp. z o.o. should be:

  • for NO-BAKE technology ≥ 5 mm
  • for metal mould technology ≥ 5 mm

 

For aluminum castings with wall thinnesses below 5 mm, we suggest redesigning the castings so that the wall thickness is ≥ 5 mm.

 

We perform aluminum heat treatment according to the following conditions: T1, T4, T5, T6, T64, T7.

  • T1 controlling cooled with a casting and naturally aged;
  • T4 supersaturated and naturally aged when needed;
  • T5 controlling chilled with a casting and artificially aged or obsolete;
  • T6 supersaturated and completely artificially aged;
  • T64 supersaturated and artificially aged;
  • T7 supersaturated and artificially outdated.
      

The aluminum foundry is equipped with the following resistance and induction melting furnaces:

  • Induction furnace (2 pcs.) with a capacity of 150 kg of aluminum and power of 250 kW;
  • Resistance furnace (1 pc.) with a capacity of 200 kg of aluminum and power of 50 kW;
  • Resistance furnace (2 pcs) with a capacity of 300 kg of aluminum and power of 60 kW.
     

Depending on technology of execution our production capability starts from following weights:

  • 0.1 - 150 kg produced in gravitational metal moulds: manual; pneumatic; hydraulics,
  • 0.1 - 500 kg produced in the so-called urethane technology "NO BAKE" with the use of chemosetting resins in sand molds using a EUROTEK mixer-spreader with a capacity of 5000 kg mass/ hour.

Machining

Casting CNC machining is executed using the following CNC machines:

 

  • CNC lathe: CNC Turret VTL-801E - turning diameter: D=1300 mm,
  • CNC milling machine: YT1500LF - size of the working table: 1854/610 mm,
  • CNC milling machine: AVIA VMC 650 - size of the working table: 650/540/620, maximum load 620 kg.

 

We have the following measuring equipment:

 

  • FARO Prime 1.8, computer-aided 5 axis measuring arm (checking dimensional and geometric tolerances of raw and CNC machined castings),
  • 3-point Vogel and 2-point Mitutoyo bore gauges (precise checking of machined hole diameters),
  • The measuring machine and measuring frame from Baces with a measuring range of 2600 mm and an accuracy of 0.06 mm.

Quality control

Quality of our products is controlled by the following the guidelines of ISO 9001:2001 procedure and stable assurance of high and stable level of quality. By executing the Quality Policy we wish to obtain the mark of firm which steady raises products quality as well as the satisfaction of our customers and our employees.

 

The quality control and quality goals are being carried out by the following concepts:

 

  • The rich experience of our employees in various parts of firm's performance
  • Co- operation with such firms which privide the quality products and services for our firm
  • Application and documenation of actions raising the quality
  • Monitoring of the world's technology progress
  • Use of the newest since achievements and steady imporvemement of our own production possibilities
  • Use of Just-in-Time concept according to Lean Managment System 
  • Prevention of araising the flawed products and services not meeting the demands of our customers
  • Control and minimization of costs in the place they occur
  • Reduction of negative influence of technological process on natural environment

 

The highest products quality is supported by testing raw (input) materials and casting samples with use of GNR Solaris NF spectrometer and by checking castings dimensional tolerances (before and after CNC machining) on the computer-aided 5-axis FARO Prime 1.8 measuring arm.

 

 

 

Picture #3. On the left, equipped with Instytut Wdrożeń i Technologii Sp. z o.o. Solaris NF GNR spectrometer and on the right a computer-aided 5-axis FARO Prime 1.8 measuring arm.

 

The Quality Management System is used to implement the Quality Policy in accordance with the requirements of the PN-EN ISO 9001: 2001 standard.

Portfolio

Aluminium Alloys

Hereby we present aluminum alloys that are being used for production of aluminum castings by Instytut Wdrożeń i Technologii Sp. z o.o. 

 

NUMBER CHEMICAL SYMBOL   NUMBER CHEMICAL SYMBOL   NUMBER CHEMICAL SYMBOL
EN AC-21000 AlCu4MgTi   EN AC-44200 AlSi12(A)   EN AC-46400 AlSi9Cu1Mg
EN AC-21100 AlCu4Ti   EN AC-44300 AlSi12(Fe)   EN AC-46500 AlSi9Cu3(Fe)(Zn)
EN AC-41000 AlSi2MgTi   EN AC-44400 AlSi9   EN AC-46600 AlSi7Cu2
EN AC-42000 AlSi7Mg   EN AC-45000 AlSi6Cu4   EN AC-47000 AlSi12(Cu)
EN AC-42100 AlSi7Mg0,3   EN AC-45100 AlSi5Cu3Mg   EN AC-47100 AlSi12Cu1(Fe)
EN AC-42200 AlSi7Mg0,6   EN AC-45200 Al5Cu3Mn   EN AC-48000 AlSi12CuNiMg
EN AC-43000 AlSi10MG(a)   EN AC-45300 AlSi5Cu1Mg   EN AC-51000 AlMg3(b)
EN AC-43100 AlSi10Mg(b)   EN AC-45400 AlSi5Cu3   EN AC-51100 AlMg3(a)
EN AC-43200 AlSi10Mg(Cu)   EN AC-46000 AlSi9Cu3(Fe)   EN AC-51200 AlMg9
EN AC-43300 AlSi9Mg   EN AC-46100 AlSi11Cu2(Fe)   EN AC-51300 AlMg5
EN AC-43400 AlSi10Mg(Fe9)   EN AC-46200 AlSi8Cu3   EN AC-51400 AlMg5(Si)
EN AC-44000 AlSi11   EN AC-46300 AlSi7Cu3Mg   EN AC-71000 AlZn5Mg
EN AC-44100 AlSi12(B)            

Contact

Instytut Wdrożeń i Technologii Sp. z o.o.
inż. Władysława Rogowskiego 16 B street
27-200 Starachowice, Poland

 

VAT PL 664-18-37-456 | REGON 291033962 | KRS 0000109383

 

 For contact in english please refer to Mr Maciej Dutkiewicz.

  

Waldemar Nowak
Production director

waldemar.nowak@iwit.pl
phone +48 606 615 871

Robert Trzos
Head of aluminum foundry

robert.trzos@iwit.pl
phone +48 664 920 658

 

Maciej Dutkiewicz
Chief Executive Officer

maciej-dutkiewicz@iwit.pl
phone +48 791 339 123

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