Custom Iron Castings Company
Manufacturing Process of Cast Iron Parts
Iron Sand Casting
Iron Sand Casting uses sand to make the mold. Hot, liquid iron is then poured right into the mold. After the iron cools and hardens, we take the part out. Workers then clean and finish the final casting.
Low Mold Cost: Making the sand molds is cheap. Plus, we can reuse the sand many times.
Works for Big Parts: This method is great for making medium to large iron parts. It handles complex shapes very well.
Flexible Runs: It is easy to use for small jobs, mid-size orders, or huge production runs.
Iron Shell Mold Casting
Iron shell mold casting is a high-quality process. It uses a thin shell made from refractory materials. Workers make this mold shell by putting many layers of a special coating onto a pattern.
Small Batches: This method is great for small jobs or making high-value iron parts.
Size Range: We use it to make both small and medium-sized iron castings.
Complex Shapes: It is the best choice for making iron castings that have very complex designs.
Iron Lost Foam Casting
Iron lost foam casting starts with a foam model. Workers put a coat of sand over this model to make the mold. The key is that we do not remove the foam model. The hot, liquid iron burns the foam away as it pours in.
Complex Parts: This method is great for making iron castings with complex shapes right away.
Lower Cost: It lowers costs and makes production much faster.
Part Size: It works well for making small and medium-sized iron castings.
Heat Treatment
Heat treatment changes the inside of iron parts. It uses steps like heating, holding heat, and cooling. This process makes the metal better. It improves how parts work, helps them last longer, and makes them easier to shape.
It makes cast iron parts harder and stronger.
It improves the toughness of cast iron parts.
It boosts the wear resistance and corrosion resistance of cast iron parts.
Machining
Machining is a final step for cast iron parts. It uses fine tools to improve the parts. This work boosts the accuracy, makes the surface much cleaner, and improves what the casting can do.
It makes the final look better.
It improves the part's structure and function.
It lets us make thin walls and complex shapes.
Surface Treatment
Surface treatment changes the outside of iron castings. It uses physical, chemical, or mechanical methods. This work boosts the casting's quality. It also makes parts last longer and improves how they look and function.
It makes the surface harder.
It improves the part's look and boosts its size accuracy.
It improves adhesion and resistance to corrosion (rust).
Different Materials of Iron Castings
Gray Iron Casting
Gray iron offers medium strength and casts easily. It moves heat well, takes shock easily, and fights wear. It is cheap to use. This makes it good for making large, complex castings.
Top Features of Gray Iron:
Easy to Cast: It flows well. This helps us make large parts with complex shapes.
Absorbs Shock: Graphite inside the iron gives it great shock-absorbing power.
Fights Wear: It is perfect for parts that rub, like engine cylinders and brake discs.
Moves Heat Well: It works for parts that must move heat away fast.
Easy to Machine: It has medium hardness. This means tools wear less when we shape the part.
Simis Gray Iron Parts Include:
Brake discs, engine cylinders, machine tool beds, pump housings, valve bodies, and pipe systems.
Gray Iron Grades Simis Uses:
ISO 185 / EN 1561: EN-GJL-100 to EN-GJL-350.
ASTM A48: Class 20 to Class 60.
DIN: GG-10 to GG-35.
JIS G5501: FC100 to FC350.
Ductile Iron Casting
Ductile iron uses a special agent (like magnesium) to create round graphite balls. This is better than the flakes found in gray iron. These balls remove stress points. This lets ductile iron combine the best traits of cast iron with the strength of steel. It offers high strength, toughness, and casts easily. It also resists wear and handles machine work well. Ductile iron performs like steel but costs less. This makes it perfect for complex, high-reliability parts.
Key Strengths of Ductile Iron:
High Strength and Toughness: The round graphite stops cracks from starting. This makes the iron much stronger and tougher than gray iron. It can stretch over 20%.
Easy to Cast: It flows very well. It also shrinks less than cast steel. This makes it easy to cast complex, thin, or very large parts.
Great Wear Resistance: Its tight structure and the graphite itself act like a good lubricant. This makes it ideal for parts that deal with friction.
Good for Machining: Even with its high strength, it is still easy to machine.
Handles Vibration: It keeps the good vibration and heat control of cast iron. It is better than cast steel in these areas.
Ductile Iron Parts from Simis:
Automotive parts (crankshafts, steering knuckles, differential housings), gears, large farm machinery parts, valves and pipe systems (like water mains), rollers, and pressure housings.
Ductile Iron Grades Simis Uses:
ISO 1083 / EN 1563: EN-GJS-350-22 to EN-GJS-800-2.
ASTM A536: 60-40-18 to 120-90-02.
DIN: GGG-40 to GGG-80.
JIS G5502: FCD400 to FCD700.
Austempered Ductile Iron Casting
Austempered Ductile Iron (ADI) is a top-tier material. It gains its high strength, toughness, and wear resistance from a process called austenitic austempering. We use this heat treatment on high-quality ductile iron. ADI does not need a change in its chemistry. Instead, this unique process creates a structure known as "ausferrite." ADI works better than standard ductile iron. It often beats many forged and cast steels. This makes it perfect for parts that need to be light, strong, and low-cost.
Why ADI is Superior:
Super Strong and Tough: Its unique structure gives it very high strength (up to 1600 MPa) and great toughness. It can stretch well. This strength-to-weight ratio beats aluminum and cast steel.
Great Wear Resistance: It has a hard surface. It also gets harder when impacted. This makes it last two to three times longer than hardened steel against wear and impact.
Fights Fatigue: The mix of strength and toughness makes it resistant to bending and contact fatigue. This is key for parts under constant load.
Damps Vibration: It keeps the structure of graphite balls. This lets it absorb vibrations 3 to 5 times better than steel. This helps cut down on noise and shake.
Easy to Machine and Light: You can machine the part before heat treatment. Its high strength lets us make parts thinner and lighter. This makes ADI ideal for reducing weight.
ADI Parts from Simis Iron Foundry:
Gears, suspension parts, and engine crankshafts for heavy trucks and rail lines; track shoes, sprockets, and drive gears for construction equipment; cutting tools and gears for farm machinery; high-performance reducer gears; camshafts; and mining parts that need high safety.
ADI Grades Simis Uses:
ASTM A897M: Grade 1: 1250/850/10 up to Grade 5: 2300/1850/ --.
ISO 17804/EN 1564: EN-GJS-800-8 up to EN-GJS-1600-1.
Alloy Cast Iron Casting
Alloy cast iron is not standard iron. We make it by adding one or more special elements. These elements include chromium, nickel, molybdenum, and copper. This step greatly improves key traits like wear, heat, and rust resistance. We pick the right alloy based on where the part will be used—like the type of wear or the heat level. This process makes parts much better than plain cast iron. It meets the needs of very tough jobs.
Alloy Iron's Best Features:
Great Wear Resistance: We add elements like chromium. These make very hard carbides. This greatly boosts resistance to wear and tear. It is needed for heavy jobs, like mining.
Good Heat Resistance: We add elements like silicon. These form a protective film on the surface. This film stops more rust and helps the part resist high heat. It is perfect for furnace parts.
Fights Rust Well: Adding elements like nickel helps the metal fight corrosion. This boosts its resistance to acids, alkalis, and salt water.
Higher Strength: Alloying makes the internal structure finer and stronger. This gives the iron better strength, hardness, and durability.
Best Overall Performance: By using several alloys at once, we can build parts with great wear, heat, and rust resistance all at once.
Alloy Cast Iron Parts from Simis:
Wear-Resistant Parts: Rollers, Shot Blasting Blades, Liners, Slurry Pump Casings.
Heat-Resistant Parts: Boiler Grates, Heat Exchangers, Furnace Floors, Flue Gates.
Corrosion-Resistant Parts: Chemical Valves, Pump Casings, Pipes, Pickling Tanks.
Special-Use Parts: Machine Tool Guides, Cylinder Liners, Automotive Camshafts.
Alloy Cast Iron Grades Simis Uses:
-- For Wear Resistance
High Chromium Cast Iron: ASTM A532 Class III Type A, KmTBCr26.
Nickel-Chromium Cast Iron (Ni-Hard): ASTM A532 Class I Type A, Ni-Hard 4.
-- For Heat Resistance
Medium Silicon: RTSi-5.5 (about 5.5% Silicon).
High Aluminum: RQTAI22 (about 22% Aluminum).
Chromium: RTCr16 (about 16% Chromium).
-- For Corrosion Resistance
High Silicon Cast Iron: ISO 2892 Grade F15 (about 15% Si). It is known for fighting acid very well.
Gray Iron Casting
Gray iron offers medium strength and casts easily. It moves heat well, takes shock easily, and fights wear. It is cheap to use. This makes it good for making large, complex castings.
Top Features of Gray Iron:
Easy to Cast: It flows well. This helps us make large parts with complex shapes.
Absorbs Shock: Graphite inside the iron gives it great shock-absorbing power.
Fights Wear: It is perfect for parts that rub, like engine cylinders and brake discs.
Moves Heat Well: It works for parts that must move heat away fast.
Easy to Machine: It has medium hardness. This means tools wear less when we shape the part.
Simis Gray Iron Parts Include:
Brake discs, engine cylinders, machine tool beds, pump housings, valve bodies, and pipe systems.
Gray Iron Grades Simis Uses:
ISO 185 / EN 1561: EN-GJL-100 to EN-GJL-350.
ASTM A48: Class 20 to Class 60.
DIN: GG-10 to GG-35.
JIS G5501: FC100 to FC350.
Ductile Iron Casting
Ductile iron uses a special agent (like magnesium) to create round graphite balls. This is better than the flakes found in gray iron. These balls remove stress points. This lets ductile iron combine the best traits of cast iron with the strength of steel. It offers high strength, toughness, and casts easily. It also resists wear and handles machine work well. Ductile iron performs like steel but costs less. This makes it perfect for complex, high-reliability parts.
Key Strengths of Ductile Iron:
High Strength and Toughness: The round graphite stops cracks from starting. This makes the iron much stronger and tougher than gray iron. It can stretch over 20%.
Easy to Cast: It flows very well. It also shrinks less than cast steel. This makes it easy to cast complex, thin, or very large parts.
Great Wear Resistance: Its tight structure and the graphite itself act like a good lubricant. This makes it ideal for parts that deal with friction.
Good for Machining: Even with its high strength, it is still easy to machine.
Handles Vibration: It keeps the good vibration and heat control of cast iron. It is better than cast steel in these areas.
Ductile Iron Parts from Simis:
Automotive parts (crankshafts, steering knuckles, differential housings), gears, large farm machinery parts, valves and pipe systems (like water mains), rollers, and pressure housings.
Ductile Iron Grades Simis Uses:
ISO 1083 / EN 1563: EN-GJS-350-22 to EN-GJS-800-2.
ASTM A536: 60-40-18 to 120-90-02.
DIN: GGG-40 to GGG-80.
JIS G5502: FCD400 to FCD700.
Austempered Ductile Iron Casting
Austempered Ductile Iron (ADI) is a top-tier material. It gains its high strength, toughness, and wear resistance from a process called austenitic austempering. We use this heat treatment on high-quality ductile iron. ADI does not need a change in its chemistry. Instead, this unique process creates a structure known as "ausferrite." ADI works better than standard ductile iron. It often beats many forged and cast steels. This makes it perfect for parts that need to be light, strong, and low-cost.
Why ADI is Superior:
Super Strong and Tough: Its unique structure gives it very high strength (up to 1600 MPa) and great toughness. It can stretch well. This strength-to-weight ratio beats aluminum and cast steel.
Great Wear Resistance: It has a hard surface. It also gets harder when impacted. This makes it last two to three times longer than hardened steel against wear and impact.
Fights Fatigue: The mix of strength and toughness makes it resistant to bending and contact fatigue. This is key for parts under constant load.
Damps Vibration: It keeps the structure of graphite balls. This lets it absorb vibrations 3 to 5 times better than steel. This helps cut down on noise and shake.
Easy to Machine and Light: You can machine the part before heat treatment. Its high strength lets us make parts thinner and lighter. This makes ADI ideal for reducing weight.
ADI Parts from Simis Iron Foundry:
Gears, suspension parts, and engine crankshafts for heavy trucks and rail lines; track shoes, sprockets, and drive gears for construction equipment; cutting tools and gears for farm machinery; high-performance reducer gears; camshafts; and mining parts that need high safety.
ADI Grades Simis Uses:
ASTM A897M: Grade 1: 1250/850/10 up to Grade 5: 2300/1850/ --.
ISO 17804/EN 1564: EN-GJS-800-8 up to EN-GJS-1600-1.
Alloy Cast Iron Casting
Alloy cast iron is not standard iron. We make it by adding one or more special elements. These elements include chromium, nickel, molybdenum, and copper. This step greatly improves key traits like wear, heat, and rust resistance. We pick the right alloy based on where the part will be used—like the type of wear or the heat level. This process makes parts much better than plain cast iron. It meets the needs of very tough jobs.
Alloy Iron's Best Features:
Great Wear Resistance: We add elements like chromium. These make very hard carbides. This greatly boosts resistance to wear and tear. It is needed for heavy jobs, like mining.
Good Heat Resistance: We add elements like silicon. These form a protective film on the surface. This film stops more rust and helps the part resist high heat. It is perfect for furnace parts.
Fights Rust Well: Adding elements like nickel helps the metal fight corrosion. This boosts its resistance to acids, alkalis, and salt water.
Higher Strength: Alloying makes the internal structure finer and stronger. This gives the iron better strength, hardness, and durability.
Best Overall Performance: By using several alloys at once, we can build parts with great wear, heat, and rust resistance all at once.
Alloy Cast Iron Parts from Simis:
Wear-Resistant Parts: Rollers, Shot Blasting Blades, Liners, Slurry Pump Casings.
Heat-Resistant Parts: Boiler Grates, Heat Exchangers, Furnace Floors, Flue Gates.
Corrosion-Resistant Parts: Chemical Valves, Pump Casings, Pipes, Pickling Tanks.
Special-Use Parts: Machine Tool Guides, Cylinder Liners, Automotive Camshafts.
Alloy Cast Iron Grades Simis Uses:
-- For Wear Resistance
High Chromium Cast Iron: ASTM A532 Class III Type A, KmTBCr26.
Nickel-Chromium Cast Iron (Ni-Hard): ASTM A532 Class I Type A, Ni-Hard 4.
-- For Heat Resistance
Medium Silicon: RTSi-5.5 (about 5.5% Silicon).
High Aluminum: RQTAI22 (about 22% Aluminum).
Chromium: RTCr16 (about 16% Chromium).
-- For Corrosion Resistance
High Silicon Cast Iron: ISO 2892 Grade F15 (about 15% Si). It is known for fighting acid very well.
Application of Iron Castings
Custom Iron Castings by Simis Iron Foundry
Iron Castings Company's Custom Steps
Confirm Manufacturing Requirements for Cast Iron Parts
Design Review and Samples
Simis engineers first check the 3D and plane drawings. This makes sure your design is ready for manufacturing. If you have a sample part, we can make the new parts based on that sample.
Define Part Requirements
We confirm what the part needs to do. This includes things like its strength, hardness, wear, and rust resistance. We also set the exact size, tolerance, and finish quality needed.
Confirm Casting Material
Our engineers help you pick the right cast iron material. This choice depends on where the part will be used and your technical needs. We give advice based on material cost, strength, and resistance to wear or rust.
Choose the Casting Method
We select the best casting process for your part. We base this choice on your price goal, the part’s shape, its required accuracy, and the material.
Make Molds and Samples
We build the casting molds using your approved drawings or samples. Then, we cast the first batch of samples using the chosen material and process.
Full Sample Inspection
The finished samples go through a full check. This confirms they meet all design standards and your quality demands. We give you reports covering size, performance, material makeup, and non-destructive testing.
Mass Production of Cast Iron Parts
Mass Production
After you check and approve the sample, we start the mass production plan. We get all the materials ready based on your order. We use the exact same machines and process as we did for the sample. This makes sure every single part we make is the same.
Quality Control During Production
We run tight quality checks while making the parts. We pull parts for checks often during the process. We test their size, look, and strength. This ensures every batch of cast iron parts is consistent and meets your needs.
Final Product Quality Inspection
We use multiple inspectors for the final check. They do many tests on the finished product. These tests cover size accuracy, surface quality, and part strength. This step makes sure all cast iron parts meet your quality standards.
Packaging and Delivery
We securely package and ship all approved parts. We pick the right packaging to prevent damage during shipping. We also choose the best delivery method (air, sea, or land) to get your parts to you on time.
To order custom parts, please email us your design drawings and 3D models. Our team will review the detailed part parameters and the 3D model to provide you with an accurate quote.