KSB: Quality in casting the safe basis

In its video, KSB points out the importance of quality as guarantor for reliability and a long service life -- especially in pressure retaining parts, an impeller or a worm wheel. Nowadays these components are manufactured from cast material to yield mo[u]ld quality. Modern technologies entail the need for flame-proof, gas-tight materials with smooth surfaces that endure extreme loads and circumferential speeds. That is why quality is KSB's primary concern from the start of its existence as well as ensuring quality from the outset of the production process. Thus quality enforcement starts at the pattern stage in which state of the art CAD tools are employed. The design is perfected in an intensive dialog between the designer and the pattern maker. Modern measurement techniques in permanent operation serve to eliminate all deviations which are out of bounds and to readjust the production process. A production planning system takes care of customer guidelines and specifications, ensures that no transmission errors occur, and collects all the data reflected in the manufacturing document. The next step is the production -- almost all parts(components) are manufactured by KSB itself in its own foundry under computer supervision (monitoring). In 30 seconds an x-ray (fluorescent) analy(s|z)er determines if material still has to be added and communicates the values back to the foundry. Thus a perfect chemical composition is achieved before mo[u]lding to satisfy narrow tolerance limits. Additional quality checks aim at analy(s|z)ing mechanical properties and the crystalline structure.

The individual steps in production are: melting (Erschmelzen), sampling (Probeentnahme), quick analysis (Schnellanalyse), tapping (Abstich), casting (Abguß, Abguß Hauptprüfung), and mechanical testing (Mechanische Prüfung).

Under these circumstances KSB produces more than 22 000 tons of goods like pump casings in a variety of over 40 alloys every year. A number on each part together with correspondingly numbered melting reports serve for later identification. Annually over 25000 different (active?) patterns are machined with a range of different tools from hand equipment to computer controlled systems.

As repetitive checking is a prerequisite for quality, a comprehensive final checking is carried out prior to delivery by means of simple visual inspection to endoscopy of the pressure retaining parts, ultrasonic testing and radiographic inspection.

Defective parts are set aside if necessary, defective spots are ground and repaired. Of course KSB does not solely rely on in-house testing: incoming castings as well go through (thorough) inspections. KSB is DIN/ISO 9002 certified and meets all the requirements asked for in DIN 50049. All this makes up the image of quality, safety and reliability that KSB stands for.