Northern Iron & Machine - Grey Iron Casting

Iron Castings

Iron casting is a hardened product derived from the mixture of iron and carbon, which can be easily cast into a mold, boasting higher carbon content than steel, typically ranging from 2 to 4.3%.

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Types of Casting Processes

The casting process dates back thousands of years to the early epochs of written history. Archaeological discoveries have documented the use of casting over 6000 years ago, around 3000 BC or BCE.

Sand Casting

Sand casting involves pouring liquid metal into a sand mold that contains a hollow cavity of the desired shape, allowing it to solidify. It is a traditional manufacturing process.

Forging

Forging is a metalworking process that manipulates, shapes, deforms, and compresses metal to achieve desired forms, configurations, or appearances as per specific designs or diagrams.

Die Casting

Die casting is a high-pressure method that forces molten metal into a mold to produce dimensionally accurate precision parts with high-quality finishes. It is ideal for mass production due to its ability to produce detailed components.

Investment Casting

Investment casting uses a ceramic shell built around a wax pattern to produce very uniform, smooth surfaces without parting lines, mold half marks, or deformities. The wax pattern is created from an aluminum die.

Ductile Iron

Ductile iron is characterized by its high strength, ductility, and wear resistance. Spherical (ball-shaped) graphite within the metal provides resistance to impact and elongation and withstands everyday use.

Ductile iron castings offer low melting points, good fluidity, and machinability, combining the engineering advances of steel, including high strength and wear resistance. This results in higher tensile and yield strength with lower damping capacity.

Also known as nodular or spheroidal graphite iron, ductile iron has unique properties due to spheroidally formed graphite. This is achieved by adding a small but specific amount of magnesium to the molten iron, altering the graphite formation.

The commonly established properties are tensile strength, yield strength, and percent elongation, well-correlated with Brinell hardness due to the influence of spheroidal graphite.

Advantages of Ductile Iron Castings

Ductile iron offers numerous advantages, such as low melting points, good fluidity, high strength, ductility, and wear resistance, resulting in higher tensile and yield strength as well as lower damping capacity.

Ductile Iron Castings Microstructure

Ductile iron, also called nodular or spheroidal graphite iron, contains spheroidal graphite due to a magnesium addition, leading to unique properties and altering the graphite's form within the metal.

Tensile & Yield Strength

Ductile iron has a minimum tensile strength of 60,000 psi and a minimum yield strength of 40,000 psi, featuring well-correlated tensile properties and Brinell hardness due to the spheroidal graphite.

Low Damping Capacity

Ductile iron's relative damping capacity measures at 0.14, significantly less than that of gray iron (1), but it compares favorably to steel alloys. Damping capacity helps in absorbing vibrations by converting mechanical energy into heat.

For many years, Zen Young Foundry has offered customized metal casting services across various industries and projects.

We provide customized metal casting services for several industries:

• Pump & Valve Parts
• Compressor Parts
• Train & Railway Parts
• Cylinder & Gear Box
• Mining & Engineering Machinery Casting Parts
• Auto & Aerospace Parts

If you need more details, please visit grey iron casting company.

The material for sand casting molds is sand, not ceramics. Due to sand's roughness, sand casting is mainly used for larger castings with lower precision requirements.

Shell mold casting is akin to sand casting but uses a thin-walled shell mold formed from a sand-resin mixture around a pattern. The metal pattern forms multiple shell molds, allowing high production rates and complex geometries.

Investment casting, or lost wax casting, involves heating metal to a molten state, pouring it into a mold, and making jewelry or complex-shaped metal parts. The negative space within the mold is appropriately gated to ensure complete filling.

Die casting forces molten metal under high pressure into a cavity, shaped by two hardened tool steel molds, similar to injection molds. This method efficiently produces metal castings.

Lost foam casting is an evaporative pattern casting method that excels in complex and precise molds. Unlike traditional methods, it eliminates the need for pattern removal, allowing the metal to fill the mold as the pattern evaporates.

We select casting methods based on the product's shape, material, and working conditions, ensuring quality through years of experience.