Casting Processes for Grey Cast Iron - HEBEI YOGEM

08 Jul.,2024

 

Casting Processes for Grey Cast Iron - HEBEI YOGEM

Casting Processes for Grey Cast Iron: A Comprehensive Overview

Grey cast iron is widely used in a variety of industries due to its unique properties, including excellent castability, high wear resistance, good machinability, and superior vibration damping capacity. Given its widespread usage, understanding the casting processes involved in creating components from grey cast iron is crucial. This article provides a comprehensive overview of those processes.

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Sand Casting

Sand casting is the most common method used to cast grey iron. This process involves creating a mold from a mixture of sand, clay, and water, which is then packed around a pattern made to the shape of the desired component. Once the pattern is removed, molten grey iron is poured into the mold. After the iron cools and solidifies, the sand mold is broken away to reveal the cast part.

Sand casting is an inexpensive and versatile process, suitable for both small and large components. However, the surface finish and dimensional accuracy of sand-cast parts are generally not as high as those produced by other casting methods.

Die Casting

Die casting is another method used for grey iron, although it&#;s more common for non-ferrous metals. In this process, molten grey iron is forced into a reusable metal mold under high pressure. This allows for excellent detail and dimensional accuracy, and a good surface finish. However, die casting is generally more expensive than sand casting, primarily due to the high cost of the dies.

Shell Mold Casting

Shell mold casting is a variant of sand casting that offers improved dimensional accuracy and surface finish. In this process, a sand-resin mixture is pre-heated and formed around a pattern. The heated sand-resin mixture hardens to form a shell, which is then separated from the pattern and joined with another shell to form the mold. Molten iron is poured into the mold, and after solidification, the shell mold is broken to release the cast part.

Lost Foam Casting

Lost foam casting, also known as evaporative pattern casting, involves creating a foam pattern which is then coated with refractory material. This coated pattern is placed in a flask and surrounded by unbounded sand. When the molten iron is poured into the flask, the foam pattern evaporates, leaving the cast part. This method can produce parts with complex shapes and excellent dimensional accuracy without the need for cores or parting lines.

Centrifugal Casting

Centrifugal casting is used to produce cylindrical parts such as pipes. In this process, molten grey iron is poured into a rotating mold. The centrifugal force pushes the molten iron against the mold wall, where it solidifies. The rotational motion helps to produce a casting with a uniform thickness and density.

In conclusion, various casting processes can be used for grey cast iron, each offering unique advantages and being suitable for different applications. The choice of process depends on factors such as the complexity of the part, dimensional accuracy requirements, production volume, and cost considerations.

14 Different Types of Casting Processes

Casting is a basic manufacturing procedure that entails molding molten material into the desired shape inside of a mold. There are different types of casting processes, including: sand casting, die casting, and investment casting. Each method offers various solutions for various industries while boasting its own advantages and disadvantages. For example, sand casting involves creating a mold out of sand, while die casting involves using metal molds for high-volume production. Investment casting is known for its intricate designs, which combine wax patterns with ceramic molds.

Listed below are 14 different casting techniques, their definitions, importance, and brief discussions on how they work. 

1. Sand Casting

The versatile metal forming technique of sand casting uses non-reusable sand molds to produce intricate metal castings. It's an essential method for creating metal parts in various sizes, ranging from ounces to tons. This technique is indispensable in many different industries because it excels at shaping alloys with high melting temperatures, such as: steel, nickel, and titanium. Inexpensive and recyclable materials are combined to make up molding sand with exceptional heat resistance. Silica is the preferred casting sand, though chemically bonded systems and green sand are also used. The effectiveness of the mold in maintaining its shape and producing high-quality castings depends on key characteristics like strength, permeability, and flowability. To learn more, see our guide on Sand Casting Manufacturing.

2. Die Casting (Metal Die Casting)

Die casting is a precision-focused manufacturing process that involves melting a metal with low melting point and injecting it into a long-life die-casting mold. These steel molds, which are created using cutting-edge techniques like CNC machining, guarantee high levels of accuracy, precision, and repeatability when creating metal components. The process has a long history that dates back to the 19th century. It has developed into two separate procedures: hot chamber and cold chamber die casting. Based on their different melting points, each process can handle a variety of materials, including: aluminum in cold chamber casting and alloys of zinc, tin, lead, and magnesium in hot chamber casting. Die casting finds extensive use in industries ranging from consumer and automotive products to aerospace components, making it an indispensable part of modern manufacturing. To learn more, see our guide on What is Die Casting Used For.

3. Investment Casting

Investment casting, a meticulous method, crafts ceramic molds around wax patterns, in order to serve as encasements for molten metal. Multiple wax patterns can be melted onto a gate system, and then a layered casing is created by submerging the pattern(s) in slurry and sand. After the wax is removed, molten metals like stainless steel or aluminum are poured in to create intricately detailed copies. Investment casting efficiently creates complex parts that are difficult for other processes to produce; the advantages include: undercuts, fine detail, and smooth finishes. Investment casting has developed from its ancient roots to modern applications to become an essential technique used in a variety of industries, preserving fine craftsmanship and enabling effective large-scale manufacturing. To learn more, see our guide on What is Investment Casting.

4. Gravity Die Casting

The time-tested metal casting method known as gravity die casting uses gravity to introduce molten metal into a mold's cavity. This approach, which has roots in antiquity, offers simplicity and economics. Manufacturers coat the cavity, melt the metal, pour it in, and then wait for the metal to solidify. The process uses automatic or manual machines. Positive mechanical characteristics, lower costs, and improved finishing are all advantages. The drawback of gravity die casting, however, is the length of time required to make intricate parts. Despite technological advancements, this seemingly crude method is still effective for smaller parts, finding use in a variety of applications including: kitchenware, lighting, and automobiles. Alternatives like aluminum die casting and sand casting are preferable for complex, high-volume production.

5. Continuous Casting

Continuous casting creates uniform, fine-grained, solid shapes with superior physical properties by quickly cooling molten metal inside a vertical or horizontal mold. This technique minimizes contaminants while maximizing yield because it uses gravity to ensure a steady flow. Although various configurations like squares and hexagons can be made, tubes and solids are the most typical shapes. When the metal has cooled after entering the mold and reached the desired length, it is continuously extracted. Continuous casting excels at producing high-density, pressure-resistant products for applications requiring precision and structural integrity. While continuous casting provides benefits like effective stock utilization and dimensional consistency, mold costs and suitability for particular alloys and quantities should be taken into account.

6. Shell Molding

A thin mold is made around a heated metal pattern as part of the precision casting process known as shell molding. Dry silica sand combined with a thermosetting resin forms a shell&#;that is about 6 mm thick&#;around the pattern. This shell is then dried, stripped, and joined to form a cavity for pouring molten metal. For the mass production of thin-walled castings, shell molding is the best option because it offers dimensional accuracy and a superior surface finish. Despite being more expensive than green-sand molding, it produces metallic patterns with high-quality results that guarantee intricate details and reliable results.

7. Lost-Foam Casting

In lost-foam casting, molten metal is poured into a foam mold (that evaporates during the pour) which is encased in sand. The mold is made of carved, machined, or injection-molded polystyrene foam. The waste gas can escape into the sand because the ceramic refractory coating is made permeable to a degree. The lost-foam casting process allows for complex shapes and thin walls at a lower cost and with less lead time and machining requirements than many other casting methods. Complex CAD designs and constrained part sizes, however, present difficulties. This process is used by a variety of industries, including: the arts, defense, and automotive, to produce a wide range of parts, including circuit boards, sculptures, and automobile components.

8. Pressure Die Casting

Modern metal processing methods like high-pressure die casting involve quickly and rapidly filling a mold with molten metal to create castings. It boasts strong mechanical properties, minimal machining, high production efficiency, and excellent surface finish. Key process parameters include: time, temperature, speed, and pressure. Filling capacity and specific pressure have an impact on compactness. Mold temperature has an impact on cooling speed and surface quality. The manufacturing of toys, appliance parts, and automotive housings are just a few examples that make use of pressure die casting.

9. Centrifugal Casting

The centrifugal casting method, also referred to as roto casting, is used to create thin-walled cylinders from materials like metal, glass, and concrete. It produces a fine-grained casting with rotational symmetry by rapidly rotating a permanent mold while pouring molten material. Instead of producing custom-shaped parts, the centrifugal casting method is often employed to produce standardized stock materials for further machining. It was created in by Alfred Krupp and is used to make things like pipes, flywheels, and cylinder liners.

10. Permanent Mold Casting

Permanent mold casting is a method of casting metal that produces accurate, high-quality castings using reusable molds made of materials like steel or iron. It is widely used in sectors like automotive and aerospace that demand complex shapes, large volumes, and superior mechanical properties. Cost-effectiveness, fine-grained structures, smooth finishes, and intricate designs are some of its advantages. Initial costs, a lack of material compatibility, and problems with heat transfer are obstacles. Innovations include CAD, hybrid processes, and 3D printing for making molds. Applications benefit from improved durability, accuracy, and customization in the automotive, aerospace, and medical industries. To learn more, see our guide on Permanent Mold Casting.

11. Vacuum Casting

Vacuum casting, also known as polyurethane casting or urethane casting, uses silicone molds to produce rubber and plastic components in a vacuum. This adaptable method creates bubble-free castings with smooth surfaces by mimicking injection molding. Rapid prototyping and low-volume production of complex parts benefit the most from its use. Numerous resin options are available for vacuum casting, which also has uses in the automotive, aerospace, and product design verification industries. Vacuum casting has advantages in terms of flexibility and cost-effectiveness, but it's important to take mold wear and shrinkage rate into account. The ability to produce intricate features and additive manufacturing are examples of innovations.

12. Low-Pressure Casting

Low-pressure die casting (LPDC) is a metal casting process in which molten metal is poured into a die-cast mold at low pressure, typically 20 to 100 kPa. This method continuously fills the die cavity to account for volume shrinkage during solidification, maintaining high accuracy. The castings are pure due to LPDC producing little slag and less oxidation. LPDC is particularly adept at creating intricate geometries with sharp contours and smooth surfaces. It has limitations in the production of thin-walled parts and slower cycle times, despite its benefits in accuracy and formability. Automotive parts like cylinder heads, blocks, and wheels, as well as everyday kitchen appliances like pressure cookers, are just a few examples of the many applications in which LPDC can be used. To learn more, see our guide on Low-Pressure Casting.

13. Squeeze Die Casting

Squeeze die casting, a combination of casting and forging processes, uses high pressure to solidify molten metals between hydraulic press plates. It produces nearly net-shaped casting that is almost pore-free and highly dense. The two primary types, direct and indirect, each have unique advantages. Indirect casting is similar to high-pressure die casting, whereas direct casting involves pouring metal into the die and pressing it under pressure. The process results in improved mechanical properties, shorter production cycles, and better metallic properties. Material selection varies, with aluminum, magnesium, and copper as common choices. Squeeze casting finds applications in automotive parts, aircraft components, and more. 

14. Plaster Casting

Plaster casting, also known as plaster mold casting, creates molds using a gypsum mixture and additives. A rubber or metal pattern coated with anti-adhesives serves as the mold's basis. The mold is created by pouring, setting, and removing the pattern from the plaster. The plaster is removed after the metal has cooled after being poured into the mold. It allows for intricate parts and provides precise shapes with little scrap. Plaster molds produce smooth surfaces, are disposable, and work best with non-ferrous metals. Applications include: prototypes, short-run aluminum/zinc production, gears, valves, ornaments, and lock components.

What Is Casting?

Casting is a manufacturing process that involves pouring a liquid substance into a mold with a hollow cavity that has the desired shape. The material then goes through solidification, creating a solid object that fits the shape of the mold. Numerous industries use this technique to create intricate and adaptable parts, from sculpture to automotive parts. To learn more, see our guide on Casting.

How Does Casting Work?

A series of steps are involved in casting. First, a mold that closely resembles the intended product is made, typically out of metal, sand, or ceramic. Then, a liquid substance, such as molten metal, is poured into the mold's cavity. The substance takes on the shape of the mold as it cools and solidifies. When the cast object has fully solidified, the mold is removed to reveal it. 

How Is Casting Used in Manufacturing?

Casting is a common manufacturing technique used to produce a wide variety of intricate parts and goods. Manufacturers can produce intricate geometries and precise designs by using molds to shape liquid materials like molten metal. This process is necessary for creating items with a range of dimensions, shapes, and complexity for a variety of markets, including: the jewelry, automotive, and aerospace industries.

What Industry Uses Casting?

Numerous industries, including automotive, aerospace, building, jewelry, and consumer goods, use casting extensively. For engine components, casting is crucial in the automotive industry. Casting is a key component of aerospace for complicated aircraft parts. It is used in the construction sector to adorn buildings. Casting is a technique used by jewelry designers to create intricate ornaments, and consumer goods include a variety of cast items like tools and appliances.

How To Choose a Type of Casting Process?

Considerations for selecting an appropriate casting process include: material, complexity, quantity, and desired properties. Investment casting works well for complex designs, while die casting is best for mass-producing metal parts. For larger components, sand casting is more affordable, whereas precision casting offers tighter tolerances. Centrifugal casting works best for cylindrical objects, while gravity casting is appropriate for simpler shapes. To make an educated decision, assess the requirements of your project.

What Is the Most Popular Type of Casting?

One of the most well-liked and widely employed casting techniques in manufacturing is sand casting. All industries prefer it because of its flexibility, efficiency, and capacity to create complex shapes. The adaptability of sand casting in terms of material choices and mold design, as well as its suitability for both small- and large-scale production, contribute to its widespread use in industries like automotive and aerospace.

What Are the Materials Used in Casting?

Materials used in casting include:

Metals: Such as iron, aluminum, copper, and zinc.

Alloys: Combining metals to enhance properties, like bronze and brass.

Ceramics: Like porcelain and clay for pottery.

Plastics: Including thermoplastics and thermosetting plastics.

Composite materials: Mixing fibers and resins for specialized applications.

Rubber: For creating flexible parts.

Glass: Used for artistic and functional objects.

Concrete: Common in architectural and decorative casting.

Is Metal Used in Casting?

Yes, casting does often incorporate metal. Metal is cast by pouring molten metal into a mold to create different shapes and objects. It is one of the most commonly employed casting materials because of its adaptability, toughness, and variety of uses in sectors like: construction, aerospace, and automotive. To learn more, see our guide on Metalloid Uses.

Is Polyethylene Used in Casting?

Yes, polyethylene is used in casting, and more specifically, polyethylene cast films are used. These films are made using a cast extrusion method, in which plastic resins, such as polyethylene, are melted and created into thin films by being extruded through a slit die. These films find use in a variety of industries, including: packaging, agriculture, and construction. To learn more, see our guide on PE Plastic.

What Differentiates Casting From Injection Molding?

Injection molding involves pushing melted material (most commonly plastic) into a mold under high pressure, as opposed to casting, which broadly involves pouring molten material into a mold and waiting for it to solidify. A wider variety of materials, including metals, and larger, more complex shapes are suitable for casting. For smaller parts, injection molding offers high precision and is an affordable option for mass production. Both approaches have specific benefits, and in some manufacturing processes, they can work well together. To learn more, see our guide on the Process of Molding.

What is Iron Casting?

Iron casting is a known procedure being done in manufacturing. This process involves melting material and poured into a mold. The hollow cavity in the mold helps achieve the desired shape of the product being produced. The material is then allowed to solidify so it will follow the pattern used. Once the material became solid, it will be taken out from the mold. This should complete the process. Iron casting is useful in producing different components that many industries can use.

There are different materials used for casting. Among these include metals and other materials that easily melt and cure when combined with other ingredients. The most commonly used materials are the clay, concrete, and plaster. If you want to achieve a complex shape or form, the cast iron is the ideal process to use. 

Properties of Cast Iron

Cast iron shows different properties that make it beneficial for manufacturing. These properties are also the reason many industries prefer iron casting over other procedures. 

Hardness 

It is resistant to abrasion and depression. It guarantees that the castings are scratch-free and smooth as needed.

Fatigue Resistant

The material can withstand the highest level of stress at many cycles without breaking. 

Toughness

Cast iron is tough and robust. It has high capacities for energy. Its durability is reliable. 

Flexibility

It can change its form without breakage. This is useful, especially when making complex forms and designs.

Elasticity

This allows the materials to go back to their original form after their deformation.

Tensile Power 

It allows the material to hold the highest level of longitudinal stress without breaking apart.

Key Benefits of Iron Casting

There are many benefits iron casting can provide. These plus points make good reasons iron casting has become popular and in demand these days.

Higher Level of Strength

Cast iron is robust. It appears to be stronger, more ductile, and stiffer than pure iron. Its strength makes it perfect in manufacturing different materials that industries can use. Cast iron&#;s durability is reliable in that they can efficiently use it in any complex design, shape, and size of the end product needed. 

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Fluidity

The best thing about iron casting is that the materials are easy to melt. This allows fluidity to be at its best, making the process easy to do and achieve. It then saves time, money, and resources as the process can produce more products in a shorter amount of time.

Useful 

Cast iron is useful as it can mold it in different shapes, sizes and forms. Any industry will find iron casting purposeful for their needs. This allows design engineers to create more products that can be of higher efficiency for the industries.

Low Maintenance

Cast iron is durable and has properties that allow it to be as useful for a longer time. Its strength and flexibility make it require little to zero maintenance. Cast iron products provide longevity with no frequent replacement or repairs. 

Types of Cast Iron

Cast iron has been widely used in commercial and consumer applications. Not known to many people, there are different types of cast iron.

1. Gray Cast Iron

This is the most common cast iron. They derived its name from the presence of small fractures which give the color gray in it. This is mostly used in many applications, especially for kitchen pans and other utensils. 

2. White Cast Iron

It may not be as popular as the gray cast iron but it still has a lot of users. The iron compounds known as cementite caused its white appearance. 

3. Ductile Cast Iron

The other term for this is nodular cast iron. Its ductility comes from the iron alloy with high levels of carbon.

4. Malleable Cast Iron

Engineers would call this type &#;workable cast iron&#;. It uses heat in making an end product.

Iron Casting Methods

There are different methods used to produce iron castings. They based the choice of method to use on the type of product to be made.

Sand Casting

This method is also known as sand molded casting. This method involves the use of non-reusable sand molds. Sand casting can produce different cast iron components in varieties of forms, shapes, and sizes. 

Lost Foam Casting 

This method takes on the evaporative-pattern concept. It uses foam for the patterns. Because of the low boiling point of foam. The major benefit of Lost Foam Casting is that the process becomes faster and easier to finish.

Common Applications of Cast Iron

The applications of cast iron can be vast. A lot of industries benefit from it which is why its popularity and demand in the market remained in good standings. Among the common applications of cast iron include:

This is used in making anchors for ships

It is useful in pipe production

It can be used in making automotive parts,such as gear

This is most useful in producing pots and other kitchen utensils

It is used in making some household appliances and tools

Cast iron provides a lot of purposes for different industries and trades. Design engineers rely on this process because of its efficiency. Today, there are a lot of iron casting providers in the market. Choosing the best company will give you the best cast iron services you will need.

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Cast iron castings, cast iron parts - Metal foundry ...

Cast iron castings have such a long tradition in the metalworking industry. It is very common in metal foundries for various applications. From outdoor urban furniture, marine, to kitchen accessories, we all see cast iron parts from cast iron foundry manufacturers.

Cast Iron castings are very popular in metal foundries and greatly contribute to numerous fields in our daily life. There is a range of applications we see every day that are from cast iron casting foundry manufacturers such as lamp post, counterweight, manhole cover, bench, urn planter, etc.

Stay with us to get more understanding about the Cast iron castings industry and cast iron castings manufacturers.

What is cast iron castings?

Cast iron castings are the metalworking activity commonly see in the metal foundry manufacturers. Its processes include melting cast iron material, filling the molten fluid to the mold, and forming the casting parts.

Iron casting has a very long tradition dated back to BCE and nowadays the cast iron castings put great contributions to a range of life applications. We can see there are a lot of products coming from casting cast iron foundry manufacturers and factories.

Cast iron castings contribute greatly in a range of application

Cast iron

Cast iron definition

Cast iron is a type of iron-carbon alloy material commonly used in metalworking foundries. Cast iron is produced by smelting the iron-carbon alloy and pour into the mold.

The chemical composition of cast iron consists mainly of 95% iron, more than 2.14% to 4% carbon, 1% to 3% silicon, and other impurities such as phosphorus (P), sulfur (S), manganese (Mn).

Type of Cast iron

Cast iron is divided into different types mainly based on the content of Carbon, Silicon, and other impurities.

RANGE OF COMPOSITIONS FOR TYPICAL CAST IRONS
VALUES IN PERCENT (%)

Cast iron typeCarbon (C)Silicon (Si)Manganese (Mn)Sulfur (S)Phosphorus (P)Grey Cast Iron 2.5-4.01.0-3.00.2-1.00.02-0.250.02- 1.0Ductile Cast Iron 3.0 -4.01.8-2.80.1-1.00.01- 0.030.01-0.1White cast iron1.8-3.60.5-1.90.25-0.80.06-0.20.06-0.2Malleable cast iron2.0-2.90.9-1.90.15-1.20.02-0.20.02-0.2

Cast iron properties

RANGE OF TYPICAL CAST IRON PROPERTIES

Cast iron type Cast iron PropertiesGrey Iron Good machinability; Good thermal conductivity; High compressive strength; Low tensile strength; Good resistance to galling and wear; BrittleDuctile Iron High ductility; High strengthWhite ironHigh compressive strength; Difficult to machine; Good hardness; Resistance to wearMalleable ironHigh ductility; Tougher than gray cast iron; Be twisted or bent without fracture; Excellent machining capabilities

Factors affecting the properties of cast iron

Chemical composition

  • Carbon (C): is the element that promotes the graphite process. The higher the carbon percent is, the lower ductility and thermal conductivity. If the carbon contained in the cast iron is in the form of cementite, it is called white iron; and if the carbon is in the form of graphite, it is called grey iron. The formation of different types of cast iron depends on its chemical composition and cooling rate.
  • Silicon (Si): Silicon is the element that most affects the crystal structure of cast iron because it promotes graphitization. Increased Si content will increase dilution, abrasion and corrosion resistance of cast iron. Usually, the Si content in cast iron is 1.5 &#; 3%.
  • Manganese (Mn): Mn in cast iron promotes the formation of white iron and prevents graphitization. Therefore, white iron usually contains 2 &#; 2.5% Mn. Oppositely, in grey iron, the amount of Mn does not exceed 1.3%. Mn is to increase abrasion resistance, durability; and to reduce the harmful effects of Sulfur.
  • Phosphorus (P): P is a harmful element in cast iron. It reduces the strength and increases the brittleness of cast iron that causes cracking of the casting. However, P increases fluidity, this effect is used to cast statues and fine art details. In the case of casting thin parts, the P content in important parts should not exceed 0.1%, while the unimportant ones can be up to 1.2%.
  • Sulfur (S): is a harmful element in cast iron. It prevents graphitization, thus reducing dilution, and thereby reducing castability. So the S content in cast iron is not more than 0.1%.

Cooling rate

The factor that influences the crystal structure of cast iron is the solidification and cooling condition of the casting. If you cool it quickly, you get white iron, if you cool it slowly, you get gray iron. The cooling rate of the cast iron depends on the type of casting pattern and the thickness of the casting.

Castability of Cast iron Types

Grey Iron Casting

Grey iron casting

Grey iron has the best casting properties due to its low melting point, high flowability, and easy casting of complex products. The shrinkage of grey cast iron is small, sometimes creates a concentrated shrinkage indent but can be controlled by the technical tips.

Grey cast iron castings, due to the graphite presence it has good shock absorption; plus due to their high fluidity, complex castings can be cast easily. The good castability and low cost make grey iron become one of the most commonly used alloys in metalworking foundries as well as cast iron foundry manufacturers.

Grey iron is classified into different grades depending on the tensile strength and properties. Grey iron grates of GG10, GG15, GG20, GG25, GG30 (ASTM standard) are mostly used in casting parts for a range of uses.

Some grey iron casting applications can list such as street furniture, lamp post, fence, bench, urn planter, gas accessories, pump housing, engine cylinder blocks, flywheels, gearbox cases, machine-tool bases, etc.

White iron Casting

White iron is hard and brittle plus large shrinkage so that it is less preferable in casting parts. We can see some of the bearing surfaces using white iron casting but not popularly.

Ductile iron casting

Ductile iron has high mechanical properties comparable to that of steel. At the same time, due to its good casting properties, it is often used in manufacturing complex parts instead of steel.

The main use of ductile iron is to make parts that require high tensile loads and high impact (such as steel) and easy to shape by casting method at the same time.

The typical ductile iron castings made of ductile iron is the crankshaft. It is a part with a complex shape, with great load and impact, good resistance to wear. If made of steel (for example C45), large billets through forging must be pressed on large presses, which requires cutting. If replacing with ductile iron casting, the somewhat simpler device produces the casting closer to the finished product and therefore lower machining costs. The ductile iron is also well-known and preferred by cast iron foundry manufacturers in casting manhole cover due to its good loading capacity.

Why cast iron castings are popular?

A cast iron urns made by VIC

Among materials, the cast iron castings are mostly seen in metal casting foundries due to its excellent casting ability. With its range of great properties, cast iron castings perform great advantages in numerous applications.

  • Firstly, with the combination of high carbon content and silicon, cast iron has excellent cast-ability. This material has the ability to cast under different heat treatments and processing techniques. Hence it allows casting different products coming various in styles designs.
  • Secondly, cast iron, in general, has good fluidity, low shrinkage, low melting point, easy to fill in molds. It is a very good compression material, good static load, and abrasion resistance.
  • Thirdly, cast iron is very durable over time. Hence it is pretty suitable for outdoor street furniture applications.
  • Finally, cast iron is divided into different types with typical properties so that foundries can use flexibility in various applications.

The disadvantage of cast iron castings

Except for tremendous advantage, there are some limitations remaining in cast iron manufacturing.

  • Generally, cast iron products are brittle, except ductile iron and malleable cast iron. So that it limits in some applications which require good impact resistance.
  • Additionally, white cast iron is non-machinable. While grey cast iron is cheap, ductile and malleable cast iron is more expensive.

However, these limitations are not about cast iron generally. Each type of cast iron maintains both strengths and weaknesses. Therefore, the cast iron foundry manufacturers often consider the applications, do adjust and chooses the right material in casting the provide the best quality.

Cast iron castings technique

Featured by good casting property, the cast iron products can be processed by different methods. Each cast iron foundry manufacturers own their typical cast iron casting technique and casting lines. Mostly common and economic techniques are green sand casting, lost foam casting, and furan resin sand casting. Each of these casting technologies are chosen to manufacture the specific type of applications.

  • Green sand casting: this method characterizes by versatility and reasonable cost. It is often used to cast simple detailed and small to medium-sized cast iron products. This sand casting is widely applied in cast iron foundry manufacturers because of its low cost.
Cast iron casting molding technique
  • Lost foam casting: It is advantageous by high detailed casting-ability. Hence, this technique is mostly applied for complicated designs and shapes. The final cast iron casting products maintain an excellent smooth surface finish and high precision. Also, nearly no errors and defects are found.
  • Furan resin sand casting: This casting technique is excellent in casting complex cast iron castings. It guarantees high appearance, fewer defects, and good quality for the final outcomes. However, this casting is quite expensive than these two listed above.

Cast iron parts

With great casting advantage, cast iron casting has wide applications in a range of industries. From Agriculture Machinery; Construction Industry; Transportation; Marine; Water Supply and Drainage, we all see cast iron casting parts from casting metal foundries somewhere.

With the good casting ability, it is common used to cast machines details, automotive parts, ornamental-detailed product, etc.

Cast iron casting partsCast iron kettlebell

Additionally, cast iron parts are weather-resistant, durable over time and low maintenance, therefore, they are popularly used for making outdoor street furniture applications such as lamp posts, urn planters, benches, fences, litter bins, bollards, etc.

Especially in the marine industry, cast iron is often applied to cast marine buoy counterweight, the anchor for ships, boat parts, etc. due to its corrosive resistance.

Another example cast iron parts application for kitchen furniture can be named such as cast iron pan support, cast iron gas burner, etc.

Ductile iron is a preferable material using in casting manhole cover due to its high ductility and high strength.

Cast iron foundry manufacturers

Cast iron castings are the core working fields of many metalworking foundries including us. At Vietnam Cast Iron, we are one of the OEM cast iron foundry manufacturers specialized in providing cast iron parts to the world market. Our foundry applies the three main techniques to process the cast iron casting that are green sand casting, lost foam casting, and furan resin sand casting. Each casting technique is considered to apply depending on the specific casting requirements.

Cast iron foundries

Provide the OEM service, we work on almost all cast iron casting parts either small or large details. Specifically, we have a lot of experience on casting lamp post, manhole cover, litter bin, urn planter, gas stove accessories, pump housing, fitness equipment, and so on for US and EU that get high appreciation from them. Either you have specific drawings and requirements or you need more advice on solutions, we can offer our support for even ODM service.

As one of the leading cast iron foundry manufacturers exporting to the US and EU, we control and have a tight inspection for all the manufacturing process from input to output. The raw material always has to pass the chemical composition analysis testing to make sure the input is qualified. For each casting step, we appoint an inspection manager to control all the working processes and labor techniques. Not only offer the cast iron roughcasting parts, but we are also able to provide the surface treatment and machining if there is a need.

Pan support made by VIC

VIC is one of the cast iron foundry manufacturers which always commits to deliver the best quality cast iron parts for a competitive price to our customers. At our cast iron foundry, we work with the motto that &#;Customer satisfaction is our development&#;. Hence, whatever we offer, it is of high quality; and whatever we say, it is our commitment. We treat our customers as our friends and look forward to building long-term partnerships with win-win cooperation. So, an investment with us will greatly worth it because we will never disappoint you by any means.

Check our website to see our cast iron casting ability. Leave your information or contact us, we will catch you immediately.

Reference: https://www.substech.com/dokuwiki/doku.php?id=iron-carbon_phase_diagram

For more custom grey iron cast manufacturerinformation, please contact us. We will provide professional answers.