Alloy Steel Castings
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Alloy Steel Castings
Alloy steel castings refers to metal products that are cast from various alloyed steel materials as raw materials and in various processes. Alloy steel casting is based on stainless steel casting and adds other materials to the raw materials in order to fulfil the different mechanical properties of the parts.
Compared to conventional metal casting from a single material, alloy steel casting has significantly improved the properties of steel. Its strength / hardness / toughness / wear resistance etc. have been improved. Alloy steel casting is widely used in many industries, such as automotive, aerospace, energy, etc. Alloy steel material has special properties. The material structure of alloy steel is shown below.
Material of alloy steel castings
Alloy steel is steel made by adding one or more alloying elements to carbon steel. These alloying elements include manganese/silicon/nickel/chromium/molybdenum, etc. According to the content of alloying elements, it can be divided into low alloy steel/medium alloy steel/high alloy steel. According to different uses, it can be divided into alloy structural steel/alloy tool steel/special performance steel. According to the metallographic structure, it can be divided into pearlitic steel/bainitic steel/martensitic steel/austenitic steel. According to the quality level, it can be divided into high-quality alloy steel/high-grade high-quality alloy steel.
Alloy Steel Investment Casting Samples
Prime alloy steel castings
Alloy steel castings – construction machinery
Prime alloy steel castings
Alloy steel casting – agricultural machinery
Alloy steel railway part
Alloy steel casting
Alloy Steel Investment Casting Process
Each process of our production is executed in strict accordance with the Standard Operation Procedure (SOP). The main process is as the following: Pouring simulation, Mold development, Raw material inspection, Wax pattern, Shell preparation, Metal pouring, Cleaning and Heat treatment, Inspection, Warehouse packaging, and Shipping.
Mold Development
The technical department develops the mold, and the quality department uses the three coordinates to carry out the dimensional inspection.
Wax Pattern
The workshop uses automatic waxing machines to set the waxing pressure, holding time, etc. and to produce high quality was patterns.
Shell Preparation
The workshop has 4 automatic production lines, able to produce 1800 sets of shells. We use hygrothermograph, aerometer, and PH to monitor humidity, temperature, and concentration of liquor aluminum chloride.
Metal Pouring
4 sets of 500KG furnaces are in production, and 3 sets of 500KG spare furnaces are ready when capacity increases. The operators conduct rigorous tests to fulfill material requirements.
Clean And Heat Treat
The workshop is fully equipped with 8 heat treatment furnaces, 3 quenching furnaces, 1 central shot blasting machine and 11 large shot blasting machines.
Inspection
All blank dimensions are checked using a CMM. We have rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has certified employees to do UT, PT, MT testing.
Alloy Steel Sand Casting Process
Each process of our production is executed in strict accordance with the Standard Operation Procedure (SOP). The main process is as the following: Pouring simulation, Mold development, Raw material inspection, Modeling (Core-Making), Melting, Metal pouring, Cleaning and Heat treatment, Inspection, Warehouse packaging, and Shipping.
Mold Development
Design and produce molds according to the requirements of the drawings. Generally, wood molds can be used for single-piece production, plastic molds and metal molds are made for mass production, and templates can be made for mass castings. Our mold is mainly made of aluminum.
Modeling (Core-Making)
Includes modeling (forming the cavity of the casting with molding sand), core-making (forming the inner shape of the casting), and mold matching (putting the core into the cavity and closing the upper and lower flasks). Modeling is a key process in casting.
Melting
According to the required metal composition, the chemical composition is matched, and the appropriate melting furnace is selected to melt the alloy material to form a qualified liquid metal liquid (including qualified composition and qualified temperature)
Metal Pouring
Pour qualified molten metal into the sand box equipped with the mold. The pouring stage has high safety requirement, and we have rigorous process control to protect the safety of our employees.
Clean And Heat Treat
After the molten metal is poured and solidified, the molding sand is removed, and the gate and other attachments are knocked out to form the required casting.
Inspection
All blank dimensions are checked using a CMM. We have rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has certified employees to do UT, PT, MT testing.
Application of alloy steel castings
Alloy steel castings are widely used in various fields of industry. The unique mechanical properties of alloy steel enable castings to meet different mechanical operating conditions. Alloy steel sand castings are mainly used in the following different industries.
Construction machinery industry
Applied to high-strength, wear-resistant and impact-resistant parts. Such as gears/shafts/excavator buckets/track shoes, etc.
Aerospace industry
The high temperature resistance and lightweight properties of alloy steel have made it widely used in the aerospace industry. For example, alloy steel castings are used in engine parts/landing gear/propellers and other parts.
Automobile manufacturing industry
The wear resistance of alloy steel makes alloy steel castings an important part in the automobile manufacturing industry. Its surface is smooth and delicate, and its appearance is very beautiful. Such as crankshaft/connecting rod/control arm/bracket, etc.
Shipping industry
The corrosion resistance of alloy steel materials is widely evaluated in the marine industry. Such as propeller/shaft/marine valve/pump/hull structural parts, etc.
Questions About Alloy Steel Casting Service
What Is The Difference Between High-Alloy And Low-Alloy Steel
High-alloy steels, with over 10% alloying elements, excel in applications demanding properties like corrosion resistance, high-temperature strength, and exceptional wear resistance. They are vital in industries such as aerospace for manufacturing components exposed to extreme conditions. For instance, turbine blades in jet engines benefit from the high-temperature strength of nickel-based superalloys. Additionally, high-alloy stainless steels are preferred for chemical processing equipment due to their resistance to corrosive environments.
Low-alloy steels, with less than 10% alloying elements, offer a cost-effective solution with balanced mechanical properties. They commonly find use in diverse applications such as structural construction, where their strength and affordability make them a prime choice for building components like beams and columns. In the automotive industry, low-alloy steels are used for vehicle frames and structural components, as they combine strength and weldability without significantly inflating production costs.
The choice between high-alloy and low-alloy steels ultimately hinges on specific application requirements and budget considerations, with high-alloy steels delivering superior performance in specialized applications and low-alloy steels offering a cost-effective solution with versatility for broader usage.
What Are The Common Alloy Steel?
Chromium, molybdenum, vanadium, manganese, nickel
Which Is Better, Carbon Steel Or Alloy Steel?
Low alloy steels have less than 8% total alloying elements in the composition, these steels have better hardness and resistance to wear over carbon steel but tend to have less tensile strength. The high alloy steels have more than 8% alloying elements and have better properties than those of the low alloying steels.
What Are The Advantage Of Alloy Steel?
1: High strength, good plasticity and toughness. Due to the effect of alloying elements, its strength is 25%-50% higher than ordinary carbon steel, its elongation is 15%–23%, and its impact toughness at room temperature is higher than 60J/cm^2.
2: Good weldability. Because of the low carbon content and low alloying element content, its plasticity is good, and the hardenability is low, it is not suitable for quenched structure or cracks to appear at the weld.
3: Good cold and hot pressure processing performance. Due to its good plasticity and low deformation resistance, it is not easy to produce cracks after pressure processing.
4: Good corrosion resistance. It has higher corrosion resistance than carbon steel under various atmospheric conditions.