Alloy Powder Manufacturing
Copper-based Alloy Powder at RGB is produced by Water or Gas atomization process. Copper, Lead, Tin etc., in the form of virgin metals are melted down and disintegrated into fine droplets by means of a high velocity atomizing medium. The metal droplets cool and solidify as they settle at the bottom of the atomization tank. The slurry is transferred to a dual cone drier for drying. The dried powder is sieved to get the required distribution of particles and blended to get a homogeneous mixture
Sintering
Cold rolled steel strips are prepared thoroughly for sintering. The pre-mixed bearing alloy powder is spread continuously over the moving steel strip which advances into a multi zone furnace under inert atmosphere. The powder particles reach a semi molten stage to attain metallic bond. The strip is then compacted to increase the density and re-sintered to improve the bond strength and to achieve the final desired size. The sintered bimetal strip is slit to the required width for manufacture of plain shaft bearings, bushings and thrust washers.
Babbitt Casting
Cold rolled steel strip is prepared thoroughly for casting. The bonding surface is tinned, before the Babbitt alloy is cast on the surface followed by solidification, milling and knifing to achieve the final desired size.
Pressure Sintering
Sintered bearing and anti-friction parts at RGB are also produced by Pressure Sintering method. The alloy powder is compacted to the required shape in a rigid steel carbide die using high compaction. The resultant green piece is sinter-bonded to a steel backing in a controlled atmosphere achieving metallurgical characteristics.
Electroplating
Overlay plating in an engine bearing is a thin-plated surface layer of lead-tin-copper over nickel layer (SAE-19). The Babbitt overlay provides embeddability, conformability, long life and superior performance.Tin flash is done on bushings and sliding bearings as a protective coating to improve shelf life.
Tool Room
Equipped with advanced machineries for tool manufacturing along with well qualified and experienced technical team, we manufacture and maintain dies, moulds, jigs and fixture used for various processes. From initial concept to final production, our tool room ensures that every detail of the tooling meets the required quality and precision.
Our Tool Room at a glance
- Vertical Machining Centers
- CNC Turning Centers with Auto loaders
- Electric Discharge Machines
- Cylindrical Grinding Machines
- Surface Grinding Machines
- Milling Machines
- Drilling Machines
- Tool Room Lathes
- Sandblasting Machines
Polymer Impreganation
The bimetal strip is coated with the selected polymer material. This is achieved through pressure impregnation. The impregnation process allows the polymer material to penetrate into the bronze substrate, forming a top layer which is recrystallized and calibrated to the required thickness.
Continuous Casting
Copper and other metals are melted to form a homogeneous liquid which flows out through a water-cooled mold, shaping the metal to the desired cross-section. The metal undergoes secondary cooling and the continuous strand is cut to the desired lengths. The cast strip or rod may undergo additional processes like rolling, heat treatment & surface finishing to achieve specific mechanical properties.
