Wam Metals has world-class facilities to manufacture castings, forgings, machined and assembly products. All of our processes are controlled using the ISO 9001 Quality Management System and are audited on a regular basis.

Tool-room

Our Tool-room uses the latest machining equipment and software to design and develop new products; after which they manufacture high-quality tools, dies, clipping tools, injection moulds and machining fixtures/jigs to be used for the manufacture of products. Damaged or worn tools, dies, clipping tools and machining fixtures/jigs are also repaired and refurbished in the Tool-room.

Solidworks (3D software) Design and edit 3D models used for manufacturing of tools, dies and jigs.
Mastercam (3D software) Design and edit 3D models used for manufacturing of tools, dies and jigs.
Deckel Maho 70V Manufacture and repair tools, dies and jigs.
Tongtai Machining Centre Manufacture and repair tools, dies and jigs.
Spark Eroder Create complex shapes tools, dies and jigs.
Surface grinder Prepare tools, dies and jigs before manufacture or repair.
Lathes and milling machines Manufacture and repair tools, dies and jigs.

 

Tool-room CNC machines

Tool-room CNC machines

State-of-the-art Deckel Maho machine

State-of-the-art Deckel Maho machine

Foundry

Our Foundry has the capacity to produce 125 tons of material in the form of billets and castings each month. All material is analysed using our Spectrometers before casting to ensure conformity to specification.

5 Gas crucible furnaces Manufacture castings in both sand and gravity dies.
2 Horizontal Conti-caster furnaces Continuously manufacture billets of brass and special copper alloys.
2 Induction furnaces
Furnace 1: 500kg, 250Kw
Furnace 2: 1800kg, 500Kw
1 Vertical Conti-caster furnace Manufacture special alloy rod (copper base).
1 Aluminium pressure die caster (400T)  
Sand mould manufacturing plant Manufacture sand moulds for use by the Foundry to cast sand mould products.
2 Spectrometers Analyse the chemical composition of brass and aluminium to ensure conformity.

 

Foundry casting

Crucible casting process

Foundry casting processFoundry casting processFoundry casting processFoundry casting process
 

Continuous casting process [video]


Extrusion and Reeling

Cast billets from the Foundry are extruded into various shapes (round, square, hex, sections) and sizes ranging from 15mm to 90mm. The rods (round extrusions only) are then reeled to straighten any curves in the rods.

500 Ton Extrusion Press Extrusion of rod up to 30mm diameter.
1600 Ton Extrusion Press Extrusion of rod up to 90mm diameter.
Reeling machine Reel material into straight rods up to 100mm diameter.

 

Extrusion machine

Extrusion machine

 


Forging, saws and clipping

The saws cut material to the correct length for forging (or machining). The cut billets are formed into various shapes and sizes using the forging presses; clipping presses then remove any excess material.

5 Band saws Cut material to length.
2 CNC saws Cut material to length.
23 Forging presses (90-530 ton) Manufacture forgings (hot-forging and cold-forging) in various shapes/sizes.

 

Forge-shop with 23 forging presses

Forge-shop with 23 forging presses

Saw cutting process

Saw cutting processSaw cutting process
 

Saw cutting process [video]

Forging process

Forging processForging processForging processForging process
 

Forging process [video]

Clipping process

Clipping processClipping processClipping process
 

Finishing

We offer a range of finishing options (including multiple finishing) depending on the product application and customer requirements. 

Fettling/linishing Excess material is removed after forging or casting.
Acid dipping Dipped in acid for a smooth, clean finish.
Shot-blasting Fine satin shot-blasted finish.
Polishing Polished to a shine.
Electro-plating Nickel, tin and silver plating.
Hot dip galvanising A zinc coating to protect iron, steel or aluminium from corrosion.
Powder coating Tough paint covering to protect products.
Plating plant Tin and nickel plating .

 

Shot-blasted clamps

Shot-blasted clamps


Machining

Our Machine-shop precisely machines each product to specification. All products are inspected to ensure conformity.

16 CNC Lathes Machining of products.
10 CNC Machining Centres Machining of products.
3 Special purpose machines Machining of products.
Drilling and tapping Drilling holes and tapping threads.

 

CNC Lathes and CNC Machining Centres

CNC Lathes and CNC Machining Centres

State-of-the-art 5-Axis Machines

5-Axis Machines

CNC Machining process [video]

 


Plastic Injection moulding

Our plastic injection plant manufactures plastic parts from all injection-mouldable plastics.

Demag Injection Moulding Machines 175 ton, 240 ton, 420 ton injection moulding machines.
CLF Injection Moulding Machine 125 ton injection moulding machines.
DR Boy 30 ton and 50 ton injection moulding machines.

 

Plasting injection moulding machines

Plasting injection moulding machines


Assembly

We are capable of assembling thousands of simple and complex parts per month at in our Assembly bay.

 

Assembly process [video]



Delivery

Our fleet of delivery vehicles ensures the utmost customer convenience as we deliver to your doorstep.

Delivery vehicles

 


Quality Assurance, Quality Control and Testing

 

We have an ISO9001:2015 accredited Quality Management System and we take pride in producing and supplying top quality products. Our plug and socket products are certified by MASC in accordance with SANS standards. Should you require any certificates, please contact our Sales or Quality department - Get in touch.

Our Quality department tests and approves products to statutory and customer requirements. We offer certificates of analysis, testing and conformance when requested.

Brinell Hardness Tester Test the hardness of various materials.
Rockwell Hardness Tester Test the hardness of various materials.
2 Spectrometers Analyse the chemical composition of brass and aluminium to ensure conformity.

 Quality assurance and quality control