Grey Iron Castings & Grey Iron Casting Companies

Grey, or gray, iron castings are iron alloyed parts produced in foundries, not to be confused with forges, where they are formed via closed mold operations for applications in a wide variety of industries. Industries that grey iron castings serve include agriculture, architecture, automotive, construction, electronics, irrigation, machinery construction, transportation, and ventilation. Grey iron castings lend durability and strength to any operation for which they are used.

To acquire grey iron, metalworkers must first mine iron ores or iron oxides and then process it in a special type of blast furnace, called an electric induction furnace or a cupola. The generally accepted composition of cast grey iron is 95% iron by weight, plus 1 to 3% silicone and 2.1 to 4% carbon. The high amount of silicone, which produces graphite when heated, is the element responsible for grey iron’s coloring. It manifests itself when fractures form, revealing its graphitic microstructure. The exact appearance of individual grey iron depends on both temperature and timing. Other than appearance, variable properties of castings include thermal conductivity, energy dissipation, resistance to wear and deformation, and melting point. Additional elements that may appear in grey iron castings, whether intentionally, to alter specific properties, or unintentionally, include manganese and sulfur; the latter is often added into molten iron to increase its hardness. When metalworkers have reached the grey iron mixture they want, they proceed to casting.

Some Leading Manufacturers

MES, Inc.

Lewis Center, OH | 740-201-8112

MES, Inc. is a reliable source for a broad range of cast iron products. We serve customers around the world with high quality iron castings and exceptional manufacturing services. We cast many different types of iron, including standard iron, gray iron, ductile iron, and white iron. We can handle even your most unique requirements! With machining, engineering, painting, anodizing, and assembly services, we can take on your whole project! Contact us today!

Imperial Casting Company, Inc.

Florence, AL | 256-766-8720

Imperial Casting Company has been manufacturing high quality gray iron castings for more than 46 years. We specialize in creating high strength iron castings from customers’ tooling and new tooling from blueprints or samples. We provide sand casting, green sand casting, airset sand casting, no-bake sand casting, and a multitude of secondary operations as well. Contact us to discuss your needs or visit our website to send a request for quote!

Progressive Foundry, Inc.

Perry, IA | 515-465-5697

As the premier manufacturer of iron castings, U.S. Casting Company is your source for gray iron castings of all kinds. We have been serving industrial companies around the nation for many years, so you can count on us to get the job done right every time. Using our extensive experience, highly skilled staff, and state-of-the-art equipment, we can supply you with engineered castings to your specifications. Connect with us today to find a solution for your casting needs.

Kirsh Foundry, Inc.

Beaver Dam, WI | 920-887-5261

As an ISO 9000 certified company, Willman Industries is your source for reliable, high-quality iron castings. We specialize in casting components for mining, oilfield, heavy-machinery, and transportation industries as well as many others. We manufacture 19 grades of grey iron castings and 20 grades of ductile iron, so we can create a cast iron product to fit your application requirements. Check out our website or call us today for more information!

Decatur Foundry, Inc.

Decatur, IL | 217-429-5261

As a world-class supplier of all kinds of cast metal parts and products, Decatur Foundry, Inc. is your reliable source for high-quality gray and ductile iron castings. With a state-of-the-art casting facility, we can create practically any cast iron product you could ever need, and we have the equipment to provide additional machining and finishing services to satisfy all of your requirements. And with a focus on customer service, competitive pricing, and on-time delivery, we are the right source for your cast iron product needs!

Iron foundry workers have a variety of processes at their disposal with which to produce grey iron castings, though they all more or less follow the same basic procedure. First, the grey iron is liquefied, then it is poured into a mold, where it is allowed to cool then ejected.

Different grey iron casting processes include centrifugal casting, die casting, and sand casting.

Centrifugal casting is a method used to cast cylindrical parts and components that produces fine-grained outer surfaces with even dispersion. To work, liquefied grey iron is poured into a mold that rotates at high speeds as it is introduced. Centrifugal casting stands apart from many other types of casting because it is mainly used to create stock materials for further machining, as opposed to parts shaped for specific applications. Grey iron castings made via this process can also be almost any diameter, length, and thickness.

Next, die casting is popular for continuous cycle or the fast production of castings. It uses reusable molds that are made in the shape of the desired finished product. These molds, or dies, are formed out of two hardened tool steel dies.

Sand molding is a low-cost and low-maintenance casting option that uses a sandy mixture as a mold. The four main mixtures from which manufacturers may choose are called no bake, dry sand, skin-dried, and green sand.

No bake molds are disposable molds, made of sand, a quick-setting resin, and a catalyst. They are formed with the help of a casting flask, which is usually made out of plastic, wood or metal. No bake molds employ a heat-free, cold-setting casting process.

During dry sand molding, unbonded sand is mixed with an adhesive or a chemical binder, shaped to form a mold and then baked a certain temperature to finish. To make castings, molten grey iron is poured into the mold, taking its shape.

To create a mold using the skin-dried molding method, also known as air-dried molding, operators mix water, sand, a binder like clay and bonding additives and then dry it with a torch or heating lamp.

Green sand molds are made the same way, minus the bonding additives and the heat drying.

No matter the method chosen, it is many times the case after casting that the newly formed castings need to undergo secondary processes to finish them and to remove imperfections like burrs and scale. These processes include deburring, annealing, machining, galvanizing, painting, and more. To create more finished products, most iron foundries have the equipment and staff available to perform such processes in-shop.

The applications of grey iron castings are many. As non-flammable building components, they provide superior fire protection to wooden support structures. Also, their graphite content is useful in energy dissipation of parts like engine blocks and crankshafts, which depend on the dampening of mechanical vibrations. Grey iron castings are also frequently used to make cases, dies, pipes, and decorative embellishments.

Imperial Casting Company, Inc.

Grey Iron CastingsGrey Iron Castings – Imperial Casting Company, Inc.