Cast Iron

A reliable source for Grey Iron Castings information and leading Grey Iron Castings Companies & Manufacturers.

While there are several specific casting techniques in use to produce cast iron parts, all follow this basic procedure of heating, molding, cooling and ejecting. Read Moreā€¦

Cast Iron Cast iron encompasses a large group of ferrous alloys containing between 1 and 3 % silicone and 2 to 4% carbon with a core of about 95% iron by weight.

Leading Manufacturers

Bremen, IN  |  800-837-2411

As a foundry & machine shop, BCI Solutions continues to grow and diversify. Customers receive world class green sand casting and precision CNC machining under one roof! Founded in 1939 with an emphasis on using recycled ferrous material, we are a fourth-generation family business that produces complete assembled, precision gray, and ductile iron castings.

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BCI Solutions $$$

Webster City, IA  |  515-832-1722

Seneca Foundry is a manufacturer of gray and ductile iron castings, ranging in size from ounces to 250 pounds. Our customer base is from a wide range of industries, such as agriculture, industrial, cookware and more. We offer a variety of molding processes including green sand, lost foam, and no-bake. Our versatility enables us to give the customer the best solution for their casting needs. Contact us today to get started!

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Seneca Foundry, Inc. $$$

Waupaca, WI  |  715-258-6611

Waupaca is a TS-16949, ISO 14001, and OHSAS 18001 certified producer of gray, ductile and compacted graphite iron castings melting over 9,500 tons per day. These castings are produced using vertical, high pressure, greensand molding at all of our facilities utilizing several different mold sizes to optimize the production of castings ranging from 2 pounds (1Kg) to 350 pounds (160 Kg).

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Waupaca Foundry, Inc. $$$

Hanover, PA  |  717-632-4165

As a leading manufacturer of grey and ductile iron castings, Penn-Mar Castings has lead times as low as three weeks and the ability to pour castings ranging from 150 to 3,000 pounds. Our foundry uses a no-bake method to produce both complex cores as well as simple shapes. By determining the lowest scrap rate and reducing machining time, we offer long-term savings without compromising quality.

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Penn-Mar Castings, Inc. $$$

Commerce City, CO  |  303-288-8221

At Precise Cast, we do post finishing and assembly service, 4th axis machining and 3D surfacing. We use magnesium, aluminum and zinc alloys and have machining solutions for product development and engineering inquiries. We also do plaster and sand casting as well as high quality prototypes that will meet or exceed your expectations.

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Precise Cast Prototypes & Engineering $$$

Cedar Grove, WI  |  920-668-8526

Willman stands for quality grey iron castings that you can count on for many years to come. As a leading manufacturer producing all types of precision components, weighing from ounces to 40,000 lbs, Willman can satisfy your demands for complex engineering solutions. Willman employs skilled workers & the most advanced equipment for economical production, giving you the quality assurance you want.

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Willman Industries, Inc. $$$
placeholder image BCI Solutions Seneca Foundry, Inc. Waupaca Foundry, Inc. Penn-Mar Castings, Inc. Precise Cast Prototypes & Engineering Willman Industries, Inc.

There are two predominant types of cast iron, those being grey iron and white iron. The former has a graphitic structure, the deflection of which provides the namesake color on fracture surfaces. White iron, however, has small white deposits of cementite rather than being completely pallid. The main differences between the two are silicone content and cooling times, both of which have a significant impact on the physical and mechanical behavior of the alloy.

White iron has a low carbon content and is cooled at a fast rate to produce a brittle cast part with good hardness and abrasion resistance. These are used in a number of wear applications such as slurry pumps, liners, grinding mills and pulverizers. Grey iron castings on the other hand are produced through the slow cooling of high carbon iron alloys and are less brittle allowing their use as crankshafts, support beams, engine blocks and more.

In addition to these two types, iron foundries and metallurgical engineers continue to develop more malleable and ductile irons that exhibit the beneficial characteristics of cast iron, but with significant reductions to brittleness due to a spheroid rather than flaked internal structure. These specialized alloys are becoming increasingly common in the industrial world.

Although pure iron is found only in meteorites, the element is one of the most abundant on Earth making up 5% of the crust and 35% of the total mass. Mining operations extract the element from iron ore and oxides such as magnetite, hematite, limonite, goethite and siderite which contain high levels of iron. These oxides are smelted to produce what is known as pig iron, the base material for cast iron.

The stock forms are heated in a special blast furnace known as a cupola. Scrap iron and steel are added to the molten mixture to produce cast iron. Once in a molten state this metal is poured into a cast where it is cooled at controlled rates before a finished or near finished part is ejected or extracted. Some of the more popular methods used today for iron castings are die casting, centrifugal casting and sand casting.

Die casting is used to manufacture complex parts at high production rates, centrifugal casting creates cylindrical parts and sand casting uses expendable synthetic or natural sand molds to create rough parts. These processes result in easily machined cast iron components with high compression strength, low melting points, good thermal conductivity and energy dissipation, wear resistance and fluidity.

Cast Iron Informational Video