Custom Ductile Iron Parts Manufacturer
Ductile Iron Parts
China Simis Company is a specialized OEM custom casting manufacturer of Ductile Iron (DI) Parts (also known as Nodular Cast Iron). DI is a high-performance ferrous alloy renowned for its exceptional strength, toughness, and ductility, often serving as a cost-effective alternative to cast and forged steel.
We utilize a wide range of casting techniques to produce reliable, high-integrity DI components, including structural parts, housings, valves, and transmission elements for the automotive, energy, and heavy machinery industries worldwide.
What Casting Processes Are Used for Ductile Iron Parts Production?
Ductile Iron’s excellent castability allows for flexibility in manufacturing processes, enabling us to optimize production based on part size, complexity, required precision, and volume. The main casting processes we apply include sand casting, shell mold casting, lost foam casting, and precision CNC machining, each tailored to different product specifications and production needs.
| Manufacturing Process | Application Focus for DI Parts | Core Advantage |
| Sand Casting | Large, high-mass structural components, heavy truck parts, machinery frames. | Cost-effective for complex shapes and large sizes, essential for high-volume iron production. |
| Shell Mold Casting | Components requiring improved surface finish and tighter as-cast tolerances (e.g., pump housings, manifold connections). | Better dimensional control and reduced machining allowance compared to sand casting. |
| Lost Foam Casting | Parts with intricate internal passageways, hollow sections, or complex cores (e.g., exhaust manifolds, hollow shafts). | Eliminates traditional core assembly, allowing for highly complex, single-piece designs. |
| Precision CNC Machining | Mandatory finishing step for critical interfaces, bore diameters, and bolt patterns. | Guarantees the True Position and flatness required for flawless assembly. |
What Are the Key Material Properties and Grades of Ductile Iron Parts?
The unique spherical (nodular) graphite structure in DI prevents crack propagation, giving it properties closer to steel than traditional Gray Iron. We produce various grades to meet specific mechanical requirements (e.g., strength vs. toughness), including high strength grades, high toughness grades, and corrosion resistant grades for diverse industrial applications.
| Material Grade Focus | Primary Performance Requirement | Typical Ductile Iron Application |
| High Strength Grades (e.g., 100-70-03) | High tensile strength and yield strength. | Gears, crankshafts, connecting rods, and high-pressure housings. |
| High Toughness Grades (e.g., 60-40-18) | Superior ductility and impact resistance. | Axle components, suspension parts, and heavy-duty chassis brackets. |
| Corrosion Resistant Grades | Resistance to chemical attack and severe environments. | Water treatment valves, pump housings, and petrochemical piping components. |
How to Ensure Quality Control and Metallurgical Integrity of Ductile Iron Parts?
The quality of DI hinges on precise control over the magnesium treatment process and the resulting microstructure. We implement a comprehensive set of quality control measures including nodularity verification, mechanical testing, non-destructive testing, and heat treatment capability to guarantee the performance and reliability of every ductile iron part.
·Nodularity Verification:
Routine metallurgical analysis ensures the graphite is predominantly in the required spheroidal (nodular) form to maximize ductility and strength.
·Mechanical Testing:
Providing certified Material Test Reports (MTRs) documenting tensile strength, yield strength, and elongation (ductility) according to ASTM or ISO standards.
·Non-Destructive Testing (NDT):
Utilizing Ultrasonic Testing (UT) and Magnetic Particle Inspection (MPI) to verify structural integrity, ensuring parts are free from critical defects and porosity.
·Heat Treatment Capability:
Offering supplementary heat treatments (such as normalizing or quenching/tempering) to further enhance strength or surface hardness (excluding ADI, which is a specialized category).
What Are the Key Application Areas of Ductile Iron Parts?
Our custom Ductile Iron (DI) castings are essential across diverse sectors, offering a superior balance of strength, ductility, and cost-efficiency in safety-critical and heavy-duty applications. The main application areas include automotive chassis & suspension, water treatment & piping, agricultural machinery, pumps & hydraulics, power transmission, and construction & earthmoving industries.
| Application Sector | Typical DI Component | Primary Operating Challenge | Ductile Iron Grade Focus |
| Automotive Chassis & Suspension | Steering Knuckles, Control Arms, Brake Calipers (Fixed/Heavy-Duty). | High Impact Load, Fatigue Resistance, Safety-Critical. | ASTM 60-40-18 (Maximum Toughness). |
| Water Treatment & Piping | DI Pipes and Fittings, Gate/Butterfly Valve Bodies, Pump Casings. | Corrosion Resistance, High Water Pressure Sealing, Long-Term Underground Service. | ASTM 80-55-06 (Pressure Rating). |
| Agricultural Machinery | Tractor Axle Housings, Plowshares, Tillage Components, Linkages. | Extreme Impact Load, Soil Abrasion, Fatigue Resistance. | ASTM 60-40-18 (Impact Resistance). |
| Pumps & Hydraulics | Valve Bodies, Hydraulic Pump Housings, Flanges. | High Pressure Containment, Zero Leakage, Fluid Media Tolerance. | ASTM 80-55-06 (Structural and Pressure). |
| Power Transmission | Crankshafts, Gearbox Housings, Transmission Cases, Couplings. | High Strength, Rigidity, NVH Damping. | ASTM 80-55-06 or Q&T Grades. |
| Construction & Earthmoving | Track Shoes, Heavy-Duty Brackets, Crane Counterweights. | Extreme Weight Load, Shock Load, Durability. | ASTM 80-55-06 (High Structural Strength). |
What Are the Advantages of Simis OEM Customization for Ductile Iron Parts?
Partnering with Simis for custom ductile iron parts delivers core engineering and commercial benefits, including steel substitution solutions, design flexibility, integrated process control, and performance tuning to meet the specific needs of your applications.
·Steel Substitution:
We offer expertise in converting complex steel fabrications and forgings into cost-effective DI castings, often providing comparable performance at a lower unit cost.
·Design Flexibility:
DI’s castability allows for highly complex geometries, internal passages, and weight reduction features not feasible with forging or fabrication.
·Integrated Process Control:
We maintain strict control over the entire production cycle, from raw material induction and nodulizing treatment to final machining and NDT, ensuring consistent quality and performance.
·Performance Tuning:
We select the specific DI grade and adjust the casting parameters to provide the optimal balance between strength and toughness required by your application's unique load profile.
How to Get a Quote for Custom Ductile Iron Parts?
China Simis Company is your expert global partner for custom casting Ductile Iron Parts, engineered for superior strength, high toughness, and outstanding cost efficiency.
Please submit your 2D technical drawings, 3D models, and specific mechanical requirements (e.g., minimum yield strength, required elongation) to our engineering department for a consultation and detailed quotation.
