Ductile Iron Casting
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About Ductile Iron Casting
Ductile iron casting is a type of cast iron renowned for its distinct microstructure. The graphite in ductile iron casting appears as small nodules, imparting superior properties compared to conventional cast iron. These nodules enhance flexibility and strength, making ductile iron casting highly versatile across industries like automotive, engineering, and construction. Its exceptional mechanical properties make it a top choice for critical components requiring both strength and ductility.
Ductile Cast Iron Casting Process
The main process we use is ductile iron sand casting process.
The ductile iron casting process involves several key steps, each critical to achieving the desired material properties:
- Selection of Raw Materials: Unlike common gray cast iron, ductile iron casting requires specific types of ductile iron, such as the commonly used 18# ductile iron. The process begins with a careful selection and proportioning of raw materials based on their chemical composition.
- Molding Process: The molding technique for ductile iron differs from that of regular gray iron due to the higher shrinkage rate of ductile iron. This requires an increase in the size of risers to ensure adequate iron flow and compensate for shrinkage in the mold. Moreover, the nature of ductile iron mandates the use of specific molding sands, like resin or water glass sand, rather than cement sand, and high-temperature resistant refractory coatings.
- Melting and Casting Process: Strict control over the chemical composition of ductile iron is essential during the melting phase. The casting process follows the principle of high-temperature melting and low-temperature pouring. It’s important to ensure that each riser is adequately filled with molten metal and continually supplied until the metal in the riser no longer decreases in volume.
Through these steps, ductile iron casting produces a metal with superior durability and wear resistance, suitable for various high-performance applications.
High-quality sand casting mold
Design and produce molds according to the requirements of the drawings. Generally, wood molds can be used for single-piece production. Our mold is mainly made of aluminum.
Cast ductile iron mold (core)
Modeling: forming the cavity of the casting with molding sand.
Core-making: forming the inner shape of the castin.
Mold matching: putting the core into the cavity and closing the upper and lower flasks.
Melting of ductile iron raw materials
According to the required metal composition, the chemical composition is matched. After that, we select the appropriate melting furnace to melt the alloy material.
Pouring of ductile iron
Pour qualified molten metal into the sandbox equipped with the mold. The pouring stage has high safety requirements. We have rigorous process control to protect the safety of our employees.
Post-cleaning and heat treatment of customized ductile iron castings
After the molten metal is poured and solidified, the molding sand is removed. The gate and other attachments are knocked out to form the required casting.
Inspection
We use CMM to check all blank dimensions. After that, we have a Rockwell hardness machine, dynamic balance instrument, roundness meter. Basically, the company’s quality department has certified employees to do UT, PT, MT testing.
Custom Iron Castings: Ductile Iron Grades
| Iron
Grade |
ASTM A536 Standard (MPa) | ISO 1083 Standard (MPa) | Chinese GB Standard (MPa) | Yield Strength (MPa) | Hardness (HB) | Impact Toughness (J) |
| 60-40-18 | 414 | ≥400 | ≥400 | 276 | 170-229 | 7.0 |
| 65-45-12 | 448 | ≥450 | ≥450 | 310 | 187-241 | 10.0 |
| 80-55-06 | 552 | ≥500 | ≥500 | 379 | 217-269 | 15.0 |
| 100-70-03 | 689 | ≥600 | ≥600 | 483 | 255-302 | 25.0 |
| 120-90-02 | 827 | ≥700 | ≥700 | 621 | 302-363 | 35.0 |
| 140-110-01 | 965 | ≥800 | ≥800 | 689 | 341-444 | 45.0 |
| 160-135-04 | 1103 | ≥900 | ≥900 | 758 | 400-512 | 50.0 |
Samples of Ductile Iron Castings
The Advantages of Ductile Iron Casting
Good Mechanical Properties
Iron is a material that has good high-temperature ductility and high hardness and tensile strength after cooling. It has a wide range of material applications and is extremely durable, which also makes its application in a wide range of industries.
Superior Corrosion Resistance
Ductile iron casting products are corrosion-resistant in terms of material. Especially in the automotive automation industry, ductile iron parts have obvious advantages in thermal conductivity/heat dissipation.
Precision in Manufacturing and Complex Shapes
Iron materials have good ductility when heated to high temperatures. This also makes it suitable for producing various parts with complex shapes. Iron is easier to finely work on in complex knotted details.
Excellent Lubrication Characteristics
Ductile iron cast parts have high surface accuracy. This makes it possible to reduce friction during use and extend service life. At the same time, for some parts used on the outside of mechanical equipment, it can also greatly improve the appearance of the equipment.
Questions Regarding Ductile Iron Casting Services
1. What kind of casting process do we use to produce ductile iron parts?
All in all, Dawang ductile iron foundry uses lost wax casting, sand casting, and shell mold casting processes. Further, we have been committed to providing high-efficiency and high-quality ductile iron casting.
2. What kind of customer support and after-sales services do you provide as an iron casting supplier?
Dawang ensures top-notch post-sales service, promptly addressing all inquiries and concerns. Our focus on client satisfaction means swift and effective resolution of any post-purchase matters. Trust in Dawang is backed by our dedicated after-sales support.
3. What is your production capacity for ductile iron products?
Dawang guarantees a strong supply capacity for our ductile iron products. With an efficient production process, we meet diverse volume needs promptly. Our agile manufacturing ensures timely delivery, aligned with Dawang’s 21-day sample development cycle. Trust Dawang to reliably meet your ductile iron product demands.
If you have any more questions about our ductile iron casting service, please contact us now.