Iron and carbon are combined to create an iron casting, a hard material. Iron can be easily cast in a mold and has a higher carbon content than steel. The number typically ranges from 2 to 4.3 percent. After melting, the metal is poured into a mold. Wrought iron and cast iron are created in distinct ways because cast iron cannot be worked with hammers or other tools. Cast iron contains 1-3% silicon, 2-4% carbon, and other alloys, improving the liquid metal’s casting efficiency. Other compositional variations exist. Read More…
Modern Aluminum Castings Co., Inc.Terre Haute, IN | 800-467-6252
Modern Aluminum Castings Co., Inc. has been a designer and manufacturer of aluminum and iron castings since 1919. Industries served include the sporting goods, medical devices, industrial machinery, HVAC, automotive, electrical lighting, appliance, and construction industries. Other services include forgings, stampings, custom machined components, and others.$$$
Rolar Products, Inc.Muskegon, MI | 231-739-6313
Rolar Products is a job shop that manufactures products using automatic screw machines, CNC turning & milling, broaching, honing & gear cutting (hobbing) from bar stock, forgings & castings. Materials used include low & high carbon steels, aluminum, bronze, brass & burn outs. We are very diversified and produce excellent quality from an 18,000 sq. ft. facility.$$$
BCI SolutionsBremen, 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.$$$
Impro Industries USA, Inc.Diamond Bar, CA | 877-484-6776
Impro Industries is globally recognized as a leading provider of high-precision, high-complexity, and mission-critical casting and machined components. Industries served include automotive, aerospace, medical, and many mor. Our team is dedicated to the quality of our every project, ensuring the highest customer satisfaction. Contact us today to learn more about our grey iron casting capabilities.$$$
Elyria FoundryElyria, OH | 440-322-4657
Ever since our founding in 1905, it has been Elyria’s focus to put our customers first by providing high-quality, complex grey iron castings. We have a broad range of molding capabilities, enabling us to be flexible, cost-effective, and tailor our components to our customers’ needs. Elyria Foundry is ISO 9001:2008 certified.$$$
Craft Pattern & Mold, Inc.Montrose, MN | 763-675-3169
Craft Pattern & Mold, Inc. has been a leader in the grey iron casting industry since 1983. Our team is dedicated to designing and manufacturing innovative products that fit the needs of our customers. Industries we serve include electronics, medical, aerospace, automotive, and industrial.$$$
The impurities sulfur and phosphorus, as well as fluctuating concentrations of silicon and manganese, are also present in trace amounts in cast iron. Cast iron is created by reducing iron ore in a blast furnace. The liquid iron is cast, poured, and then solidified to create crude ingots known as pigs. Then, in cupola furnaces, these pigs are remelted with scrap and other alloying components, then recast into molds to create a range of items.
Mechanical Properties of Iron Casts
Hardness – Resistance of a material to abrasion and indentation
Toughness – The ability of cast iron to absorb energy
Ductility – The capacity of a substance to deform without breaking
Elasticity – The capacity of a substance to revert to its original proportions after deformation
Malleability – The capacity of a material to flex under compression without rupturing
Tensile strength – The maximum longitudinal stress that a material can withstand without breaking
Fatigue strength – The maximum stress a material can endure during a specified number of cycles without breaking
How Iron Castings are Made
Iron ore is melted in a blast furnace to produce pig iron, which is then used to make cast iron. Cast iron can also be produced by remitting pig iron or extracting it from the molten state. This process is frequently carried out with significant amounts of iron, steel, limestone, and coke, which is carbon. The undesired pollutants are subsequently removed in several procedures and confined.
Although contaminants like sulfur and phosphorus can be burned off molten iron, this has the drawback of also burning off the necessary carbon, which needs to be supplied. Carbon and silicon levels are changed depending on how the final product is used. These percentages could range from 2% to 3.5% and 1% to 3%, respectively. Before the finished product is cast, more desirable components must be added to the melt.
The casting process occurs when liquid metal is poured into a mold with a negative compression of the desired shape, typically a crucible. First, metal is poured into the mold through a spree, a hollow tube. Then, after cooling the metal and the mold, the casting's metal component is removed.
Casting is most frequently used to create shapes that would be difficult or expensive to create using other production techniques. Traditional casting methods used in this casting project include lost wax casting. This type can be further broken down into centrifugal casting and vacuum-assist direct pour casting. Sand casting and casting using a platter mold are also included.
Iron Casting Types
Gray Cast Iron
The graphic microstructure, which can fracture the material and give it a gray appearance, gives gray cast iron its distinctive appearance. As a result, this particular cast iron type is the most often utilized and widely used cast material in terms of weight. The chemical disintegration of the bulk of gray cast irons includes 2.5 percent to 4 percent carbon, 1 percent to 3 percent silicone, and the remaining iron.
Malleable iron can be produced from white iron using heat treatment. Long-term heating and cooling cause the iron carbide molecules to disintegrate, releasing free graphite molecules into the iron and combining alloys and various cooling rates resulting in a malleable iron with a microcrystalline structure.
Ductile Iron Casting
Ductile iron casting is also known as nodular cast iron and contains very small nodules of graphite arranged in concentric layers to produce the nodules. As a result, ductile cast iron possesses the characteristics of a spongy steel without the stress concentration effects brought on by graphite flakes.
- It is used to create pipes and transport appropriate fluids.
- It is utilized to create various machinery.
- It is utilized to make automotive components.
- It is used to create utensils, pots, and pans.
- It is utilized to create ship anchors.
Benefits of Cast Iron
- It offers effective casting qualities.
- Because it is readily available in huge amounts, it is mass-produced. The equipment needed for the casting process is rather inexpensive. This combination of mass production and inexpensive equipment causes its products to be inexpensive.
- Compared to steel, it offers three to five times more compression strength. It also has good machinability (gray cast iron).
- As a result of its outstanding anti-vibrational characteristics, it is utilized to create machine frames.
- It has very low-notch sensitivity and high wear resistance. In addition, its mechanical qualities are stable between 20 and 350 degrees Celsius.
- Low stress and low expense are its main characteristics.
- It is durable.
Selecting the Proper Iron Casting Manufacturer
To ensure you have the most positive outcome when purchasing iron castings from an iron casting manufacturer, it is important to compare several companies using our directory of iron casting manufacturers. Each iron casting manufacturer has a business profile page highlighting their areas of experience and capabilities, along with a contact form to directly communicate with the manufacturer for more information or request a quote. Review each iron casting business website using our proprietary website previewer to quickly learn what each business specializes in. Then, use our simple RFQ form to contact multiple iron casting companies with the same form.