MANUFACTURING AND T

Factory area
Total area 20 000 m2
Surface covered 10 000 m2
Surface for administration 1 200 m2

Our technical capabilities

Moulding department 2 rapid prototyping machines 1 supervisor
50 ton continuous mixer
20 ton continuous mixer
3 ton continuous mixer
Semi automatic box moulding line for 1850*2500 mm 20 qualified moulders
Fast loop system for cake moulds for 1400*1000 mm and core makers
Chain manipulator
Flood coating unit
Thermal reclamation unit 500kg/hour
Melting department 2 x 1500 kgs 800 kw medium frequency induction furnace 1 supervisor
1 x 1000 kgs 600 kw
1 x 500 kgs 600 kw
Bottom pouring ladles capacities -2t, 1.5t, 1t, and 750kgs 4 Flc operators
Trimming / Finishing Swing frame grinders 14 qualified fettleres
Flexible grinders
Arc cutting
Hardfacing weldings
Sand and shot blasting
Heat treatment 2 Heat treatment furnaces capacity 3,5 & 5T 1 Technician metallurgist
Machining Vertical and parallel lathes 3 Technicians
Boring, drilling machines 10 Skilled operators
Mortaiseuse, milling, CNC machines
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.
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 MACHINE
Patternless process ®

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 Mass productions parts

Numerical Control Machines 5-axis Machine

using the process patternless ®
Capacity: 10 tons
Area of work: • 2600 x 2600 x 1200 mm
• 3600 x 3600 x 1200 mm
MOULDING MACHINE
LINES SHOP
By moulding, you get pieces of small and medium Integrated machining to make finished or
series. Chemically bonded sands used to make semi-finished parts. Welding and assembly of
moulds. those parts by a wide range of processes is
possible.

Moulding plate sizes in fast loop and semi - Vertical machining

automatic lines - Numerical milling Borers l
Size of site: 1400 x 1000 - Conventional horizontal Borers
2000 x 2000 - Conventional milling
- Radial drilling,...

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 Microscope

test bars

Ultrasonic testing UTS machine Spectrometer

 PROPOSED METALLURGY
Manganese steel
AFNOR DIN 17006 ASTM
COMP. BASE % HARDNESS APPLICATIONS
A128
BASIC COMP.
C Mn CR Mo
Z 120 M 12 GX 120 Mn 12 Gr B 1.2 12.0 - - ≥400 HB jaw, hammers,
Z 120 Mc 12-2 GX 120 Mn Cr 12.2 C Gr 1.2 12.0 2.0 - By hardening Liners, blow bars, etc.
Z 120 billion12-2 GX 120 Mn Mo 12.2 MB Gr -2 1.2 12.0 - 2.0
Z 120 Mc 17-2 GX 120 Mn Cr 17.2 C Gr 1.2 17/28 2 -

Alloy steels Cr-Mo base

AFNOR DIN 17006 ASTM COMP. BASE % HARDNESS APPLICATIONS
A128 BASIC COMP.
C Mn CR Mo
212CB4 GS 42 Cr Mo 4 0.42 1.0 0.25 - 21-36 Rc Parts subjected to shock≥
50CB4 GS 50 Cr Mo 4 0.50 1.0 0.25 23-29 Rc means strong with high abrasion
NCB8052NN GX 30 Cr Ni Mo V 8 0.45 1.0 0.35 V 31-37 Rc grids Cylindrical Grinders,
30CS8 GX 30 Cr Si 7 0.30 1.0 7/8 - ≥ 48 Rc Liners

White alloy iron -Ni Cr Mo base

DESIG. FRA DIN 17006 ASTM COMP. BASE % HARDNESS FEATURES APPLICATIONS
A532 BASIC COMP
Z120 M 13 GX 120 Cr 13 - 12.0 Cr 48-52 HRC Parts subjected to cylindrical
FB 300 C13 GX 300 Cr 13 type II CL A 12.0 Cr 52-60 HRC shock low Crushers
FB 300 CD 18-2 GX 300 Cr Mo 18.2 MB CL Type II C 15.0 Cr+Mo ≥60 HRC with moderate wear Blow bars,
FB 300 CD 25-2 GX 300 Cr Mo 25.2 MB CL III type A 27.0 Cr+Mo ≥60 HRC high roller mills parts for abrasion
FB 300 CNS 9-5-2 GX 300 Cr Ni Si 952 I type CL 952 D 8.0 Cr 6.0 Ni ≥60 HRC

Stainless Steel
AFNOR DIN ASTM COMP. APPLICATIONS
C CR Neither
Z2 CN 18.8 1.4316 A351 CF3 0,02 18 8
Z6 CN 18.8 1.4314 A351 CF8 0,06 18 8 Parts subject to corrosion
Z2 CND 18-12 1.4404 A351 CF3M 0,02 18 12
Z6 CN4D 18-12 1.4401 A351 CF8M 0,06 18 12

Heat resistance steel grades

DESIG. FRA DIN ASTM COMP. BASE % BASIC COMP. TEMP.SERV.°C Rm A%
A297
C CR Neither
Z65 CN5 27.4 GX 35 Cr Ni If 27-4 HC VAR Cr 4.0 1100 480 5
Z130 CS 29 GX 130 Cr If 29 - VAR 27 - 1100 - -
Z40 CN 18.9 - HD 0.40 29.0 6.0 1100 600 16
Z40 CN 25.12 1.4825 GX 25 Cr Ni If 18.9 HF 0.25 26.0 9.0 900 600 35
Z40 CN 25-20 1.4837 GX 40 Cr Ni If 25.12 HH 0.40 29.0 12.0 1050 650 25
Z40 CN 25.20 1.4848 GX 40 Cr Ni If 25.20 HK - 25.0 20.0 1100 525 27
Z CR Ni 5050 1.4865 Ni Cr If 50-50 - - 50 50 1100 500 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 Housing

in carbon steel

Support in carbon steel Bogie plates in carbon steel

Balance plates in carbon Steel

Accessories for Housing Support in carbon steel

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 Jaw Crusher steel

in 30NCD 8M

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 Gear wheel

GS 42 Cr Mo4 FGS

Roller
Tunnel screws 42 Cr ME4 GS 42 Cr ME4 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
IVORY COAST
2009

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