MANUFACTURING AND T
Factory area
Total area
Surface covered
Surface for administration
20 000 m2
10 000 m2
1 200 m2
Our technical capabilities
Moulding department
Melting department
2 rapid prototyping machines
50 ton continuous mixer
20 ton continuous mixer
3 ton continuous mixer
Semi automatic box moulding line for 1850*2500 mm
Fast loop system for cake moulds for 1400*1000 mm
Chain manipulator
Flood coating unit
Thermal reclamation unit 500kg/hour
1 supervisor
20 qualified moulders
and core makers
2 x 1500 kgs 800 kw medium frequency induction furnace
1 x 1000 kgs 600 kw
1 x 500 kgs 600 kw
Bottom pouring ladles capacities -2t, 1.5t, 1t, and 750kgs
1 supervisor
Trimming / Finishing
Swing frame grinders
Flexible grinders
Arc cutting
Hardfacing weldings
Sand and shot blasting
14 qualified fettleres
Heat treatment
2 Heat treatment furnaces capacity 3,5 & 5T
1 Technician metallurgist
Machining
Vertical and parallel lathes
Boring, drilling machines
Mortaiseuse, milling, CNC machines
3 Technicians
10 Skilled operators
Inspection and testing
Spectro-meter
1 Laboratory Responsible
Microscope
4 Technicians
Mobile hardness tester
Measuring instruments, 3D machine, Pressure test equipements
Ultra-Sonic and magnetic particle test equipments
Impact test machine
Our metallurgies
A range of metal with high added value through flexible manufacturing:
• manganese steels
• Refractory Steel
• Stainless Steel
• Ductile Iron
• Cast Ni-resist
• 30% chromium
• other metallurgical specifications resistant to corrosion, abrasion and shock.
4 Flc operators
TECHNICAL CAPABILITSES
Mafoder specializes in the manufacture of wear iron and steel from 0,5 kg to 4 tons.
They are intended for sectors such as quarries, mining, cement, brick making, fertilizer, metallurgy and other sectors.
Mafoder now offers a range of casting including high-chromium, ductile iron and a wide range of steels including
manganese and austenitic steels.
Mafoder has positioned itself at the cutting edge of technology by investing in a rapid prototyping machines,
an innovative and revolutionary process that eliminates the manufacturing stage of wooden pattern.
The simulation is incorporated in various stages of manufacturing.
The certification of quality system Mafoder by the TUV, internationally renowned, attests to the process control and
attention given to respect our commitments in terms of delivery time, quality and price.
Mafoder is present in over 10 countries and has first rate customer.
.
For example, Mafoder received the golden trophy for export in 2001 and the OCP suppliers trophy in 2004.
RAPID PROTOTYPING
Patternless process
MACHINE
®
The machining of molds and cores directly into the sand, can eliminate the step of making wooden patterns.
This innovative technology offers the following advantages:
• Reduction of time.
• Reduction of lead manufacturing costs.
• Dimensional accuracy and surface quality.
• Improved customer service in case of last-minute change.
• Removed the cost of storage, and the risk of deformation of patterns.
Mafoder is a member of Casting Technology International Institute, and can rely on international experts for consultancy.
Unit Parts
Numerical Control Machines
using the process patternless ®
Capacity: 10 tons
Area of work: • 2600 x 2600 x 1200 mm
• 3600 x 3600 x 1200 mm
5-axis Machine
Mass productions parts
MOULDING
MACHINE
By moulding, you get pieces of small and medium
series. Chemically bonded sands used to make
moulds.
Integrated machining to make finished or
semi-finished parts. Welding and assembly of
those parts by a wide range of processes is
possible.
Moulding plate sizes in fast loop and semi
automatic lines
Size of site: 1400 x 1000
2000 x 2000
- Vertical machining
- Numerical milling Borers l
- Conventional horizontal Borers
- Conventional milling
- Radial drilling,...
LINES
SHOP
HEAT
TREATMENT FURNACES
Heat treatment options:
- Water quenching
- Air quenching
- Oil quenching
- Annealing
- Normalizing
- Tempering
- Stress relief treatment
3,5 & 5 ton capacity
LABORATORY
CONTROL
Mafoder has means to execute checks to ensure quality, metallurgical and dimensional compliance, namely:
- Mechanical tests,
- The non-destructive testing (x-ray, ultrasound, magnetic particle test, dye penetrant test)
- Held in the service of parts delivered,
- Improving the life of parts.
Muffle furnace for heat treating
test bars
Microscope
Ultrasonic testing
UTS machine
Spectrometer
PROPOSED
METALLURGY
Manganese steel
AFNOR
Z 120 M 12
Z 120 Mc 12-2
Z 120 billion12-2
Z 120 Mc 17-2
DIN 17006
ASTM
A128
COMP.
BASIC
C
Mn
GX 120 Mn 12
Gr B
1.2
12.0
GX 120 Mn Cr 12.2
C Gr
1.2
12.0
GX 120 Mn Mo 12.2 MB Gr -2 1.2
12.0
GX 120 Mn Cr 17.2
C Gr
1.2
17/28
BASE %
COMP.
CR
Mo
2.0
2.0
2
-
HARDNESS
APPLICATIONS
≥400 HB
By hardening
jaw, hammers,
Liners, blow bars, etc.
Alloy steels Cr-Mo base
AFNOR
212CB4
50CB4
NCB8052NN
30CS8
DIN 17006
ASTM
A128
COMP.
BASIC
C
0.42
0.50
0.45
0.30
GS 42 Cr Mo 4
GS 50 Cr Mo 4
GX 30 Cr Ni Mo V 8
GX 30 Cr Si 7
BASE %
COMP.
CR
Mo
0.25
0.25
0.35
V
7/8
-
Mn
1.0
1.0
1.0
1.0
HARDNESS
21-36 Rc
23-29 Rc
31-37 Rc
≥ 48 Rc
APPLICATIONS
Parts subjected to shock≥
means strong with high abrasion
grids Cylindrical Grinders,
Liners
White alloy iron -Ni Cr Mo base
DESIG. FRA
DIN 17006
ASTM
COMP. BASE %
A532
BASIC COMP
Z120 M 13
GX 120 Cr 13
12.0 Cr
FB 300 C13
GX 300 Cr 13
type II CL A
12.0 Cr
FB 300 CD 18-2
GX 300 Cr Mo 18.2 MB CL Type II C
15.0 Cr+Mo
FB 300 CD 25-2
GX 300 Cr Mo 25.2 MB CL III type A 27.0 Cr+Mo
FB 300 CNS 9-5-2 GX 300 Cr Ni Si 952 I type CL 952 D
8.0 Cr 6.0 Ni
HARDNESS
48-52 HRC
52-60 HRC
≥60 HRC
≥60 HRC
≥60 HRC
FEATURES
APPLICATIONS
Parts subjected to
cylindrical
shock low
Crushers
with moderate wear Blow bars,
high roller mills
parts for abrasion
Stainless Steel
AFNOR
Z2 CN 18.8
Z6 CN 18.8
Z2 CND 18-12
Z6 CN4D 18-12
DIN
ASTM
1.4316
1.4314
1.4404
1.4401
A351 CF3
A351 CF8
A351 CF3M
A351 CF8M
C
0,02
0,06
0,02
0,06
COMP.
CR
18
18
18
18
APPLICATIONS
Neither
8
8
12
12
Parts subject to corrosion
Heat resistance steel grades
DESIG. FRA
Z65 CN5 27.4
Z130 CS 29
Z40 CN 18.9
Z40 CN 25.12
Z40 CN 25-20
Z40 CN 25.20
Z CR Ni 5050
DIN
GX 35 Cr Ni If 27-4
GX 130 Cr If 29
1.4825 GX 25 Cr Ni If 18.9
1.4837 GX 40 Cr Ni If 25.12
1.4848 GX 40 Cr Ni If 25.20
1.4865 Ni Cr If 50-50
ASTM
A297
HC
HD
HF
HH
HK
-
COMP. BASE % BASIC COMP.
C
VAR
VAR
0.40
0.25
0.40
-
CR
Cr
27
29.0
26.0
29.0
25.0
50
Neither
4.0
6.0
9.0
12.0
20.0
50
TEMP.SERV.°C
1100
1100
1100
900
1050
1100
1100
Rm
480
600
600
650
525
500
A%
5
16
35
25
27
10
Ductile iron grades
FGS 900-2
FGS 800-2
FGS 700-2
FGS 600-3
FGS 500-7
FGS 450-10
FGS 400-15
FGS 400-18
FGS 350-22
ELEMENTS OF PUMP FOR DREDGING
& CHEMICAL INDUSTRY
Work environment:
• Seawater
• phosphoric acid segregation
• Aggression high abrasive
Materials used:
• Ferrite 30% Cr
• Stainless 25-20-4
• Stainless steel 26-5
Key features:
Very good to corrosion and abrasion
•
Pump steel 42CD4
casing
Mixer blades
in30% Cr
Impellers for phosphoric acid
segregation in 30% Cr
Stainless steel rotor
in 26-5
Bearing housings
in FGS 500-7
PARTS FOR
RAILWAY
Elements of the electric motor casing steel castings for locomotive
Housing carbon steel
Electrical motor body for locomotive
in carbon steel
Support in carbon steel
Housing
Bogie plates in carbon steel
Balance plates in carbon Steel
Support in carbon steel
Accessories for Housing
Leverage in carbon Steel
WEARING PARTS FOR
MINING, QUARRY & CEMENT INDUSTRIES
The industries that use to wear with special metallurgical mines, quarries, cement and all milling industries in general.
Mines and Quarry
Manganese steel
Example: Z120 MC 12-2, Z120 MC 17-2
Range: wear abrasion with shock and generally any place where there is impact of mass and repetitive shocks.
Heat treatment: - quenching water at a temperature of 1050 °C.
Cone Crushers (Cone)
Bucket teeth
in 30NCD 8M
Jaw Crusher steel
Cement
Refractory steel
Example: Z 40 CN 25-12, Z 40 CN 25-20, Z 40 CN 25-25. Z 80 CN 25-3
Range: strength in service at temperatures above 600 °c
• Very good resistance to oxidation and corrosion heat to a temperature of 1150 °C.
• Mechanical acceptable at high temperatures.
Cooler plates
Cooler gratings
Kiln doors assembly
Burner blocks
WEARING PARTS FOR
INDUSTRY
Industries Various
These sectors rely on steel alloy Cr, Mo, Ni and ductile iron.
Example Steel: 30 NCD 8M, 35 CSD 6M, 42 CD4M, 35NCD16M.
These parts are subject to shocks, crushing, grinding, the impact of mass,
and the impact of small particles.
Crown pinion
Wheel
GS 42 Cr Mo4
Tunnel screws 42 Cr ME4
Roller
GS 42 Cr ME4
Gear wheel
FGS
Housings
for off-shore platform
GS42 Cr ME4
STRENGTHS & EXPERIENCE
MAFODER is proud of its achievements:
• The first foundry certified in Morocco for the manufacturing and marketing of cast iron and steel by TUV.
• A production unit that respects its surroundings with a thermal sand reclamation plant and two shakeout machines
with dust collectors.
• A presence on the local market for over 20 years with first rate customers.
• A coverage of Maghreb, West Africa, Europe and the Middle East markets.
• A strong presence in markets as diverse as railway as industry phosphate, sugar, mines, quarries, cement ...
• A significant market share in ductile iron manhole covers and fittings.
THE NEDERLANDS
GERMANY
FRANCE
TUNISIA
MOROCCO
JORDAN
IRAQ
ALGERIA
UAE
MAURITANIA
SENEGAL
GUINEA
TOGO
2009
IVORY COAST
Km 9, Route d’El Jadida • Lissasfa • Casablanca • Morocco • Tél. : (212) 522 93 02 07/08
Fax : (212) 522 91 46 52 • mafoder@mafoder.co.ma • www.mafoder.com