Since our founding, we at NIDAK have utilized sand mold static casting techniques in our production, and today, we boast an extensive record of achievements as a result. The experience and expertise gained through these projects form the foundation of our capacity for small-lot, multi-product production, thereby ensuring we can continue providing our clients with exceptional quality at a competitive price.
We combine the core knowledge and experience accumulated over our many years in the industry with IT-driven casting simulations to deliver our clients with speedy and reliable solutions.
We also constantly strive to maintain the industry’s highest level of quality by looking into and adopting the latest technologies, even for secondary materials that constitute our molds, such as sands, coatings, and filters. Through this, we plan to continue expanding and evolving in the future.
In many cases, production will not begin until a fixed number of items for casting is set. Our flexible production system, however, lets us accept orders starting at a single piece. We have introduced melting furnaces with a wide range of capacities and flexibly adapt to production requirements by implementing casting plans that best meet the client’s conditions.
Designing molds for production is an extremely specialized process requiring deep familiarity with the manufacturing process and the casting itself. Our Production and Technology Department is run by a team of professionals with extensive and diverse expertise not only in drawing up designs, but also in assessing manufacturing processes, materials, testing methods and more. This allows us to provide the most effective products to meet our clients’ needs.
The sand mold static casting method allows for creating shapes not possible on bended pipes or other forged products. This includes adding a stepped structure to the inner diameter of a part or adding partial extra walls to prevent errosion from liquids. As your trusted professional for heat-resistant, corrosion-resistant, and abrasion-resistant stainless steel materials, we are more than confident you will enjoy detailed proposals that best match your usage conditions, including optimal heat treatment conditions, so as to ensure reliable, top-class quality.
Centrifugal casting is a technique where molten metal is poured in a high-speed rotating cylindrical mold. The centrifugal force then allows for forming high-quality cylindrical cast products. This method makes it possible to create a hollow cylindrical shape without using a core, thereby allowing for easily manufacturing extra-thick pipes made of special materials that are difficult to process through forging. Nidak provides both horizontal and vertical centrifugal casting. While the majority of our molds are metal, we also use sand mold centrifugal casting for some products, as it provides greater freedom in design.
Centrifugal casting is a fascinating casting method in that production of high-quality products cannot be guaranteed simply by pouring molten metal into the high-speed rotating mold. At NIDAK, we have cultivated an extensive range of in-house technologies through our many years of accumulated industry experience. This allows us to confidently supply our customers with products that exhibit the essential level of quality found in centrifugal cast products. Not only does NIDAK deliver centrifugal cast products that feature sound and uniform chemical and mechanical performance, but it also provides world-class technical capabilities for casting a diverse and varied range of materials. Our domestic and international customers have recognized the benefits NIDAK's centrifugal cast products provide to lowering their total operational costs, and we have enjoyed their continued patronage over the years as a result.
Shell mold casting is designed for mass production operations. At Nidak, we use it mainly in the production of refiner plates for the paper pulp and fiber board industries. The metal molds we use in our shell mold casting are manufactured in-house. We carry out integrated production from manufacturing new metal molds using a series of processes ranging from molding, casting and heat treating to polishing and grinding. We also manufacture stern tube liners and bent tubing for sizes compatible with shell molding production. Shell mold casting is a type of precision casting that provides the smoothest casting surfaces out of all the techniques we employ.
At NIDAK, the metal molds used in our shell mold casting are designed and manufactured in-house, which allows us to cut down on the costs for producing metal molds. We are also capable of making small modifications to the metal molds ourselves, ensuring that we flexibly meet any agreed upon date for product delivery.
At NIDAK, we utilize the technologies we have developed up until now to cast products with a blade width as small as 1.1mm (refiner blades), which was previously difficult to achieve on cast products.
Casting production comprises a variety of processes that include product design, casting, finishing, heat treatment, machining, and final product inspection. At NIDAK, we are equipped with a system capable of executing all of these processes in-house. Constructing a fully-integrated production system has allowed us to thoroughly manage the quality of all our products, while meeting the demands of our customers in a timely and flexible manner. It also allows each department to accurately and speedily share information, which has served not only to solve existing issues, but also to improve our internal communication, productivity, and technical capability.
Our comprehensive in-house production system covers all processes, which allows us to flexibly adjust and meet tight product delivery schedules. We are prepared day in and day out to meet the demands for short delivery times based on the motto of "doing all we can as a vendor to get our customers the products they need when they need them.
By executing everything from production and testing to R&D in-house, we are not only able to quickly recognize and respond to any issues that arise but also to accumulate a vast amount of knowledge and experience within the company, which translates to improvements in quality and increased productivity in our manufacturing operations.
Thanks to our in-house integrated production management system, we are able to conduct accurate and detailed management of the progress and status of production processes for each of our products. This allows us to deliver our customers with precise data as well as to provide them with peace of mind and an understanding of the status of progress for their products.
NIDAK is equipped with eight melting furnaces with the capacity to melt a wide range of volumes, starting at a minimum of 100kg to a maximum of 4,000kg. This ensures we are able to select the optimum melting weight based on each individual order. We can also adjust and run the eight melting furnaces so as to achieve increasing higher efficiency in our production. Another strength of NIDAK is our ability to handle more than 500 different materials. By using NIDAK's own AOD refining equipment to refine chips from the machining process, we are able to decarburize to around 0.02% and reuse materials so that we can provide our customers with performance that eliminates any unnecessary waste. At the same time, AOD refining allows for adjusting and optimizing the chemical composition of a product to best match the customer's application or post-processing requirements. Starting with the material itself, we work to ensure the highest level of quality in the final product.
Heat treating is an essential process in extracting the required properties out of a material. If you do not have the requisite knowledge and experience for this, you will be unable to fully elicit all the advantages found in both post-processing and the material's properties.
All of NIDAK's cast products are used in extremely severe environments. Since our founding, we have worked to build an extensive portfolio in a wide range of industries and fields. At the same time, through our research and testing, we have acquired the definitive knowledge and experience necessary to fully harness the qualities of various materials and deliver the properties and performance our customers demand.
NIDAK's vertical heat-treatment furnaces feature a special design that allows for vertically stacking cylindrical products up to 6m in length, so they can undergo heat treatment, while still maintaining their roundness.
This achieves improved efficiency for our centering operations during post-processing machining and allows for spending more working hours to ensure a high level of precision in other processes.
When quenching corrosion-resistant materials after the solution heat treatment process, it is absolutely essential to pass through the temperature range of sigma-phase precipitation as quickly as possible in order to elicit the material's desired properties. All of NIDAK's solution heat-treatment furnaces are designed to deliver rapid quenching, guaranteeing consistent quality all the way down to the metallographic structure level.
Nearly every steel product used is machined in some way from its principle material form. At NIDAK, we carry a full lineup of machining equipment and facilities that allow us to flexibly support a range of machining operations, from rough machining and finishing to beveling, drilling, and more. Through this, we are able to supply our customers with the assortment of products they desire. What is more, we tirelessly work to continue polishing and perfecting these processing technologies.
We also provide various forms of delivery to ensure that post-processing operations proceed smoothly after the product is delivered and that our customers recognize the many benefits of NIDAK products in terms of total cost.
By ordering multiple lots of our machined products, you can discover the many advantages of selecting NIDAK.
We not only meet demands for dimensional tolerance but ensure the degree of deviation between the dimensions of the delivered products is absolutely minimal. This has earned our products high acclaim among customers performing final machining by the lot, due to the streamlined setup operations they enjoy.
Our machining quality not only guarantees that demands for dimensional tolerance are satisfied, but also delivers advantages to our customer's post-processing operations.
The quality of our machining derives from the use of well-maintained, high-performance machinery as well as from the considerate and dedicated efforts of our machining experts.
Even when casting products with the same shapes and materials, there will be some slight differences between each casting due to factors such as residual stress. While today automation and the adoption of unmanned processes and operations is advancing, even machinery with the most sophisticated AI systems installed struggle to compete with NIDAK's machining experts in assessing the feelings (idiosyncrasies) of each individual casting. At NIDAK, we work to deliver our customers with a quality that is unparalleled.