Custom Steel Castings Company
Manufacturing Process of Cast Steel Parts
Steel Sand Casting
Steel sand casting uses sand to make the mold. We pour hot, liquid steel into this mold. After the steel cools, workers take the casting out. We then clean and finish the final part.
Low Mold Cost: Making the sand mold is cheap. Plus, we can reuse the sand many times.
Large, Complex Parts: This method is ideal for casting big and medium-sized steel parts. It handles complex shapes well.
Flexible Production: It works great for small jobs, mid-size orders, or very large production runs.
Steel Investment Casting
Steel investment casting makes high-quality parts. It uses molds made from wax or other items that can melt away. This method is often used for steel parts that have complex shapes and must be highly precise.
High Surface Quality: The parts come out with a very smooth finish.
Less Finishing Work: You won't need much post-processing, saving time and cost.
Best for Small Runs: It works well for small jobs that need high precision steel parts.
Steel Shell Mold Casting
Steel shell mold casting is a high-quality process. It uses a thin shell made from refractory materials. Workers build this shell by putting many coats of a special material onto a pattern.
Small Batches: This method is great for small jobs or making high-value steel parts.
Part Size: We use it to make both small and medium-sized steel castings.
Complex Shapes: It is the best way to make steel parts that have very complex designs.
Steel Lost Foam Casting
Steel lost foam casting starts with a foam pattern. The pattern is coated with a special refractory material. It is then placed inside dry sand. When hot, liquid steel is poured in, the foam pattern turns into gas. The metal then takes the place of the foam.
High Accuracy: Parts have very good size accuracy and a smooth finish. This means you need less or no machining afterward.
Complex Shapes: This method is great for complex designs and thin-walled steel parts.
Good for Medium Jobs: It works well for small to medium production runs. It also makes good use of the material.
Heat Treatment
Heat treatment changes the inside of steel parts. It uses steps like heating, holding heat, and cooling. This process makes the metal better. It improves how steel parts work, helps them last longer, and makes them easier to shape.
It makes steel parts harder and stronger.
It improves the toughness of the steel.
It boosts wear resistance and corrosion resistance (fighting rust).
Machining
Machining 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.
Different Materials of Steel Castings
Carbon Steel Casting
Carbon steel casting makes steel parts straight from methods like investment or shell casting. Carbon steel casts very well. It offers high strength and great toughness. This cast steel is much better than cast iron in terms of flexibility. It works as well as forged steel but can form complex shapes easily. This makes it perfect for parts with complex shapes that face heavy loads or hard impacts.
Easy to Cast: It flows well, even with high shrinkage. This allows us to make complex parts (we just need to add risers and chills).
Strong Overall: It mixes high strength and hardness with great ductility. It can handle impacts and fatigue loads much better than cast iron.
Easy to Weld: Medium and low carbon steel casts are very easy to weld. This helps with repair work and putting parts together.
Ready for Heat Treat: Processes like annealing or quenching can remove stress. This makes the grains finer and boosts the final strength greatly.
Carbon Steel Parts from Simis Steel Foundry:
Power plant gear (valves, pump cases, turbine cases),
Mining machines (track shoes, shovel teeth),
Heavy machines (gears, mill frames, rollers),
Ship parts (anchor chains, rudder stocks),
Train parts (couplers, side frames).
Carbon Steel Grades Simis Uses:
Low Carbon Cast Steel (Carbon ≤0.25%):
Uses: Parts needing high toughness and good welding. Examples: engine bases, ship parts, and pressure vessels.
Grades: ASTM A216 Grade WCA; EN 10293 Grade GP240GH.
Medium Carbon Cast Steel (Carbon 0.25% - 0.60%):
Uses: Parts under heavy load, fatigue, and some impacts. Examples: gears, connecting rods, and heavy mill frames.
Grades: ASTM A216 Grade WCB, WCC; ASTM A27 Grade 70-40.
High Carbon Cast Steel (Carbon ≥0.60%):
Uses: Parts needing very high hardness and wear resistance. Examples: rolls and crusher jaws.
Grades: ASTM A27 Grade 100-70.
Alloy Steel Casting
Alloy steel casting adds key elements like nickel, chromium, and molybdenum to carbon steel. This greatly improves the steel's strength, hardening ability, and performance in tough jobs. Alloy steel is stronger, tougher, and resists wear better than plain carbon steel. We can use heat treatment to custom-fit these steels for high stress, extreme heat, or wear. By mixing specific elements and custom heat treatments, we can create materials with the exact traits needed for the energy, mining, and heavy industries.
Better Strength: Adding alloys boosts the tensile strength and toughness a lot, especially for very large parts.
Great Hardenability: These elements (like Cr, Mo, Ni) let the steel harden deeper and more evenly during heat treatment. This allows for very strong, heavy castings.
Fights Wear Well: Certain mixes form hard structures that fight wear and friction very well.
Good in High Heat: It keeps its strength and resists softening or changing shape at high temperatures better than carbon steel does.
Strong in Cold: Grades with nickel keep their great impact resistance even in very cold conditions.
Alloy Steel Castings from Simis Steel Foundry:
gears, pinions, and sprockets for heavy equipment;
high-pressure valve bodies and pump cases for oil and gas;
crusher liners, shovel teeth, and mining components;
turbine cases for power generation;
high-strength parts for ships.
Alloy Steel Casting Grades Simis Uses:
High-Strength Low-Alloy (HSLA) Steels:
Uses: Structural parts, truck frames, crane arms, and mining gear where being light is important.
Grades: ASTM A148 Grade 80-50, 90-60, 105-85.
Heat-Treatable Alloy Steels (Cr-Mo / Ni-Cr-Mo):
Uses: Parts under high stress like gears, crankshafts, and pressure parts for hot service.
Grades: ASTM A217 Grade WC6 (1Cr-0.5Mo), WC9 (2.25Cr-1Mo); ASTM A487 Grade 4N (Ni-Cr-Mo).
Wear-Resistant Alloy Steels:
Uses: Crusher rolls, pulverizer hammers, and grinding parts.
Grades: ASTM A732 Grade A10; ASTM A128 Grade B-2 (12% Mn Steel - Austenitic).
Low-Temperature Nickel Alloy Steels:
Uses: Parts for storing and moving liquid gas, and offshore platforms.
Grades: ASTM A352 Grade LC2 (2.5% Ni), LC3 (3.5% Ni).
Stainless Steel Casting
Stainless steel offers great rust resistance and works well in hot or cold conditions. This mix of traits is unmatched by carbon or low-alloy steel. Picking the right stainless steel depends on the job: what it touches, the temperature, and how strong it needs to be. We can use methods like investment, shell, or lost foam casting to make rust- and heat-proof parts. This makes stainless steel perfect for parts in tough settings, high heat, or those needing very exact, complex shapes.
Fights Rust Best: Its main feature is a thin, chromium-rich layer that stops rust. This layer fights many things, like acids, alkalis, and salts.
Good in High Heat: It keeps its strength and resists scaling in high-heat environments where there is air or burning gas.
Tough in Cold: Certain grades stay very tough and won't break easily, even in super cold temperatures.
Clean and Safe: Its smooth surface is easy to clean. This makes it ideal for food, medicine, and chemical work.
Casts and Welds Well: Most grades cast easily, so we can make complex shapes. They are also easy to fix or join using common welding tools.
Stainless Steel Castings from Simis Steel Foundry:
Valves, pumps, and fittings for chemical plants;
impellers and turbine blades;
gear for food and drink processing;
marine hardware;
parts for medical tools.
Stainless Steel Grades Simis Uses:
Stainless steel is grouped by its internal structure.
Austenitic Stainless Steels:
Uses: Pump and valve bodies, chemical gear, and food processing parts.
Grades: ASTM A351 Grade CF8 (like 304), CF8M (like 316), CF3 (304L), CF3M (316L).
Martensitic Stainless Steels:
Uses: Pump shafts, valve trim, turbine parts, and mechanical parts needing high strength and some rust resistance.
Grades: ASTM A217 Grade CA15, ASTM A743 Grade CA40.
Duplex (Austenitic-Ferritic) Steels:
Uses: Pumps, valves, and fittings for offshore oil, chemical ships, and water removal plants.
Grades: ASTM A890 Grade 1B (CD3MN / like F51), Grade 4A (CE8MN / like F53).
Ferritic Stainless Steels:
Uses: Car exhaust parts (manifolds), heat exchangers, and gear used in strong acids. Good for fighting chloride stress cracking.
Grades: ASTM A743 Grade CA27M (like 430), ASTM A447 Grade G35.
Tool Steel Casting
Tool steels make tool parts that are very hard. They resist wear and stay stable even when hot. These steels are made to keep a sharp edge, avoid bending under load, and fight rubbing wear. This works at room temperature and when the part heats up. Cast tool steels cost less than forged ones. They are great for tool shapes that would be hard or costly to make by forging. Casting lets us put strong material right where it is needed. We can also add cooling channels inside the mold. This makes them perfect for making complex molds, tools, and wear parts.
Very Hard and Fights Wear: They can get and keep very high surface hardness (over 60 HRC) after heat treatment. This makes them great against rubbing wear.
Stable Size: Their size barely changes during heat treatment. This is vital for tools and dies that need high precision.
Stays Hard When Hot (Red Hardness): Certain grades keep their strength and hardness at high heat (up to 500°C–600°C). This is key for hot-working jobs.
Tough Enough: They are tough enough to take impact and shock loads without breaking or chipping.
Easy to Machine (When Soft): We can easily machine them to exact sizes while they are soft (before the final hardening step).
Tool Steel Castings from Simis Steel Foundry:
Die casting dies and cores;
forging dies and punches;
plastic injection molds;
cutting tools and blades;
wear plates and liners;
cold-work punches;
trimming dies;
hot-work extrusion dies.
Tool Steel Casting Grades Simis Uses:
Cold-Work Tool Steels:
Uses: Dies for punching and cutting, shearing blades, thread rolling dies, and gauges.
Grades: ASTM A597 Grade CA-2 (like AISI A2), ASTM A597 Grade CD-2 (like AISI D2).
Hot-Work Tool Steels:
Uses: Dies for die casting, extrusion dies, forging dies, and hot punches.
Grades: ASTM A597 Grade HA-1 (like AISI H13), ASTM A597 Grade HB-2 (like AISI H21).
Plastic Mold Steels:
Uses: Mold cores and cavities, compression molds, and mold bases.
Grades: ASTM A597 Grade P-2 (like AISI P20), ASTM A597 Grade P-4 (like AISI P4).
High-Speed Tool Steels:
Uses: Complex cutting tools, drill bits, and milling cutters. We cast them for near-net-shape parts.
Grades: ASTM A597 Grade M-2 (Molybdenum-type), ASTM A597 Grade M-4 (Higher V/C Moly-type).
Carbon Steel Casting
Carbon steel casting makes steel parts straight from methods like investment or shell casting. Carbon steel casts very well. It offers high strength and great toughness. This cast steel is much better than cast iron in terms of flexibility. It works as well as forged steel but can form complex shapes easily. This makes it perfect for parts with complex shapes that face heavy loads or hard impacts.
Easy to Cast: It flows well, even with high shrinkage. This allows us to make complex parts (we just need to add risers and chills).
Strong Overall: It mixes high strength and hardness with great ductility. It can handle impacts and fatigue loads much better than cast iron.
Easy to Weld: Medium and low carbon steel casts are very easy to weld. This helps with repair work and putting parts together.
Ready for Heat Treat: Processes like annealing or quenching can remove stress. This makes the grains finer and boosts the final strength greatly.
Carbon Steel Parts from Simis Steel Foundry:
Power plant gear (valves, pump cases, turbine cases),
Mining machines (track shoes, shovel teeth),
Heavy machines (gears, mill frames, rollers),
Ship parts (anchor chains, rudder stocks),
Train parts (couplers, side frames).
Carbon Steel Grades Simis Uses:
Low Carbon Cast Steel (Carbon ≤0.25%):
Uses: Parts needing high toughness and good welding. Examples: engine bases, ship parts, and pressure vessels.
Grades: ASTM A216 Grade WCA; EN 10293 Grade GP240GH.
Medium Carbon Cast Steel (Carbon 0.25% - 0.60%):
Uses: Parts under heavy load, fatigue, and some impacts. Examples: gears, connecting rods, and heavy mill frames.
Grades: ASTM A216 Grade WCB, WCC; ASTM A27 Grade 70-40.
High Carbon Cast Steel (Carbon ≥0.60%):
Uses: Parts needing very high hardness and wear resistance. Examples: rolls and crusher jaws.
Grades: ASTM A27 Grade 100-70.
Alloy Steel Casting
Alloy steel casting adds key elements like nickel, chromium, and molybdenum to carbon steel. This greatly improves the steel's strength, hardening ability, and performance in tough jobs. Alloy steel is stronger, tougher, and resists wear better than plain carbon steel. We can use heat treatment to custom-fit these steels for high stress, extreme heat, or wear. By mixing specific elements and custom heat treatments, we can create materials with the exact traits needed for the energy, mining, and heavy industries.
Better Strength: Adding alloys boosts the tensile strength and toughness a lot, especially for very large parts.
Great Hardenability: These elements (like Cr, Mo, Ni) let the steel harden deeper and more evenly during heat treatment. This allows for very strong, heavy castings.
Fights Wear Well: Certain mixes form hard structures that fight wear and friction very well.
Good in High Heat: It keeps its strength and resists softening or changing shape at high temperatures better than carbon steel does.
Strong in Cold: Grades with nickel keep their great impact resistance even in very cold conditions.
Alloy Steel Castings from Simis Steel Foundry:
gears, pinions, and sprockets for heavy equipment;
high-pressure valve bodies and pump cases for oil and gas;
crusher liners, shovel teeth, and mining components;
turbine cases for power generation;
high-strength parts for ships.
Alloy Steel Casting Grades Simis Uses:
High-Strength Low-Alloy (HSLA) Steels:
Uses: Structural parts, truck frames, crane arms, and mining gear where being light is important.
Grades: ASTM A148 Grade 80-50, 90-60, 105-85.
Heat-Treatable Alloy Steels (Cr-Mo / Ni-Cr-Mo):
Uses: Parts under high stress like gears, crankshafts, and pressure parts for hot service.
Grades: ASTM A217 Grade WC6 (1Cr-0.5Mo), WC9 (2.25Cr-1Mo); ASTM A487 Grade 4N (Ni-Cr-Mo).
Wear-Resistant Alloy Steels:
Uses: Crusher rolls, pulverizer hammers, and grinding parts.
Grades: ASTM A732 Grade A10; ASTM A128 Grade B-2 (12% Mn Steel - Austenitic).
Low-Temperature Nickel Alloy Steels:
Uses: Parts for storing and moving liquid gas, and offshore platforms.
Grades: ASTM A352 Grade LC2 (2.5% Ni), LC3 (3.5% Ni).
Stainless Steel Casting
Stainless steel offers great rust resistance and works well in hot or cold conditions. This mix of traits is unmatched by carbon or low-alloy steel. Picking the right stainless steel depends on the job: what it touches, the temperature, and how strong it needs to be. We can use methods like investment, shell, or lost foam casting to make rust- and heat-proof parts. This makes stainless steel perfect for parts in tough settings, high heat, or those needing very exact, complex shapes.
Fights Rust Best: Its main feature is a thin, chromium-rich layer that stops rust. This layer fights many things, like acids, alkalis, and salts.
Good in High Heat: It keeps its strength and resists scaling in high-heat environments where there is air or burning gas.
Tough in Cold: Certain grades stay very tough and won't break easily, even in super cold temperatures.
Clean and Safe: Its smooth surface is easy to clean. This makes it ideal for food, medicine, and chemical work.
Casts and Welds Well: Most grades cast easily, so we can make complex shapes. They are also easy to fix or join using common welding tools.
Stainless Steel Castings from Simis Steel Foundry:
Valves, pumps, and fittings for chemical plants;
impellers and turbine blades;
gear for food and drink processing;
marine hardware;
parts for medical tools.
Stainless Steel Grades Simis Uses:
Stainless steel is grouped by its internal structure.
Austenitic Stainless Steels:
Uses: Pump and valve bodies, chemical gear, and food processing parts.
Grades: ASTM A351 Grade CF8 (like 304), CF8M (like 316), CF3 (304L), CF3M (316L).
Martensitic Stainless Steels:
Uses: Pump shafts, valve trim, turbine parts, and mechanical parts needing high strength and some rust resistance.
Grades: ASTM A217 Grade CA15, ASTM A743 Grade CA40.
Duplex (Austenitic-Ferritic) Steels:
Uses: Pumps, valves, and fittings for offshore oil, chemical ships, and water removal plants.
Grades: ASTM A890 Grade 1B (CD3MN / like F51), Grade 4A (CE8MN / like F53).
Ferritic Stainless Steels:
Uses: Car exhaust parts (manifolds), heat exchangers, and gear used in strong acids. Good for fighting chloride stress cracking.
Grades: ASTM A743 Grade CA27M (like 430), ASTM A447 Grade G35.
Tool Steel Casting
Tool steels make tool parts that are very hard. They resist wear and stay stable even when hot. These steels are made to keep a sharp edge, avoid bending under load, and fight rubbing wear. This works at room temperature and when the part heats up. Cast tool steels cost less than forged ones. They are great for tool shapes that would be hard or costly to make by forging. Casting lets us put strong material right where it is needed. We can also add cooling channels inside the mold. This makes them perfect for making complex molds, tools, and wear parts.
Very Hard and Fights Wear: They can get and keep very high surface hardness (over 60 HRC) after heat treatment. This makes them great against rubbing wear.
Stable Size: Their size barely changes during heat treatment. This is vital for tools and dies that need high precision.
Stays Hard When Hot (Red Hardness): Certain grades keep their strength and hardness at high heat (up to 500°C–600°C). This is key for hot-working jobs.
Tough Enough: They are tough enough to take impact and shock loads without breaking or chipping.
Easy to Machine (When Soft): We can easily machine them to exact sizes while they are soft (before the final hardening step).
Tool Steel Castings from Simis Steel Foundry:
Die casting dies and cores;
forging dies and punches;
plastic injection molds;
cutting tools and blades;
wear plates and liners;
cold-work punches;
trimming dies;
hot-work extrusion dies.
Tool Steel Casting Grades Simis Uses:
Cold-Work Tool Steels:
Uses: Dies for punching and cutting, shearing blades, thread rolling dies, and gauges.
Grades: ASTM A597 Grade CA-2 (like AISI A2), ASTM A597 Grade CD-2 (like AISI D2).
Hot-Work Tool Steels:
Uses: Dies for die casting, extrusion dies, forging dies, and hot punches.
Grades: ASTM A597 Grade HA-1 (like AISI H13), ASTM A597 Grade HB-2 (like AISI H21).
Plastic Mold Steels:
Uses: Mold cores and cavities, compression molds, and mold bases.
Grades: ASTM A597 Grade P-2 (like AISI P20), ASTM A597 Grade P-4 (like AISI P4).
High-Speed Tool Steels:
Uses: Complex cutting tools, drill bits, and milling cutters. We cast them for near-net-shape parts.
Grades: ASTM A597 Grade M-2 (Molybdenum-type), ASTM A597 Grade M-4 (Higher V/C Moly-type).
Application of Steel Castings
Custom Steel Castings by Simis Steel Foundry
Steel Castings Company's Custom Steps
Confirm Manufacturing Requirements for Cast Steel 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 steel 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 Steel 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 steel 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 steel 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.