Welcome to our iron-casting manufacturing hub, where precision meets strength. Explore our diverse range of iron casting solutions, meticulously crafted to meet industry standards and your unique specifications. From alloy selection to final inspection, we ensure the highest quality at every step. Trust us to bring your vision to life with durable, reliable, and precisely engineered iron castings. Discover the excellence that defines us – your trusted partner in iron-casting innovation.
Green sand casting is a method that involves using a mixture of sand, clay, and water to create molds. The mold is created by packing the mixture around a pattern, which is then removed to create a cavity for casting. Molten metal is poured into the cavity, and the mold allows for the creation of complex intricate designs. After solidification, the sand mold is broken to retrieve the finished cast part. Green sand casting is cost-effective and versatile, making it suitable for parts in the automotive, machinery, and agriculture industries.
Chemical sand casting, also known as no-bake molding, is a method using a chemically bonded sand mixture instead of traditional green sand. Chemically Bonded sand molds are created using a wood, metal, or plastic pattern. It involves packing a mixture of sand, resin, and catalyst around a pattern, and hardening it with a catalyst. This allows greater dimensional accuracy, finer surface finish, & reduced casting defects, making it apt for high-precision applications in industries like aerospace and defense.
Air-set casting uses chemically bonded sand molds created using a mixture of sand and resin binders. The mold is hardened through exposure to air rather than heat. This method is ideal for intricate and complex parts but requires a longer curing time and additional processing steps. This process is compatible with most pattern materials to produce castings with smoother surfaces than coarse green sand. This method is slightly expensive, but is chosen when deep narrow pockets in the pattern are necessary.
| Type of Iron | Carbon | Silicon | Manganese | Sulfur | Phosphorus |
|---|---|---|---|---|---|
| Gray | 2.5 – 4.0 | 1.0 – 3.0 | 0.2 – 1.0 | 0.02 – 0.25 | 0.02 – 1.0 |
| Ductile | 3.0 – 4.0 | 1.8 – 2.8 | 0.1 – 1.0 | 0.01 – 0.03 | 0.01 – 0.1 |
| Compacted Graphite | 2.5 – 4.0 | 1.0 – 3.0 | 0.2 – 1.0 | 0.01 – 0.03 | 0.01 – 0.1 |
| Malleable (Cast White) | 2.0 – 2.9 | 0.9 – 1.9 | 0.15 – 1.2 | 0.02 – 0.2 | 0.02 – 0.2 |
| White | 1.8 – 3.6 | 0.5 – 1.9 | 0.25 – 0.8 | 0.06 – 0.2 | 0.06 – 0.2 |
| Brinell Hardness | Tensile Strength | Modulus of Elasticity | % Elongation (in 50 mm) | |
|---|---|---|---|---|
| Gray iron class 25 | 187 | 29.9 ksi | 16.1 Msi | - |
| Gray iron class 40 | 235 | 41.9 ksi | 18.2 Msi | - |
| Ductile iron grade 60-40-18 | 130 – 170 | 60 ksi | 24.5 Msi | - |
| Ductile iron grade 129-90-02 | 240 – 300 | 120 ksi | 25.5 Msi | - |
| CGI grade 250 | 179 max | 36.2 ksi min | - | 3 |
| CGI grade 450 | 207 – 269 | 65.2 ksi min | - | 1 |
A leading pump manufacturer required high-quality castings for their pump components. They needed sturdy and corrosion-resistant materials that could withstand the demanding conditions encountered in various industrial applications.
Calmet suggested utilizing gray iron for the pump components, considering its excellent castability, damping capacity, and cost-effectiveness. Working closely with the client’s engineering team, the firm manufactured custom gray iron castings that precisely met the pump’s specifications.
We employed sand casting techniques and implemented strict quality control measures to ensure the castings’ dimensional accuracy and structural integrity. They conducted thorough testing to verify the castings’ corrosion resistance and mechanical properties, ensuring they met the client’s stringent requirements.
The gray iron castings delivered by us proved to be an ideal choice for the pump manufacturer. Thanks to their exceptional strength, corrosion resistance, and ability to dampen vibrations, the pump components achieved enhanced performance and reliability.
The client was highly satisfied with the firm’s ability to deliver top-quality gray iron castings that met their specific application needs. The successful collaboration led to a long-term partnership between the pump manufacturer and Calmet.
A renowned automotive manufacturer required ductile iron castings for their latest suspension system components. The client needed materials capable of withstanding high loads, shock absorption, and maintaining dimensional stability under extreme conditions.
Calmet recommended ductile iron, known for its excellent tensile strength, impact resistance, and durability, as the optimal material for automotive suspension parts. Collaborating closely with the client’s design team, the firm designed and manufactured ductile iron castings that met their precise specifications.
Employing advanced casting techniques, including shell molding and precision machining processes, the firm ensured the castings’ dimensional accuracy and surface finish. Rigorous testing was conducted on the castings to confirm their mechanical properties, meeting the automotive industry’s stringent standards for safety and performance.
The ductile iron castings provided by our firm surpassed the client’s expectations. The castings’ high tensile strength and impact resistance contributed to the superior performance and safety of the automotive suspension system.
The client recognized us as a trusted partner for their expertise in ductile iron casting. The successful integration of the castings into their suspension components led to improved vehicle performance and increased customer satisfaction.
A mining equipment manufacturer needed white iron castings for their wear-resistant components, such as crusher liners, grinding balls, and chute liners. The client sought materials capable of withstanding severe abrasion and impact, ensuring extended service life in harsh mining environments.
Calmet proposed using white iron due to its exceptional hardness, wear resistance, and impact toughness. Working closely with the client’s engineering team, they designed and manufactured custom white iron castings optimized for the mining equipment’s specific wear applications.
The firm employed the lost foam casting method to achieve complex geometries and intricate details required by the client’s wear-resistant components. Stringent quality control procedures were implemented throughout the manufacturing process to ensure the castings’ hardness, microstructure, and dimensional accuracy.
The white iron castings supplied by Calmet proved to be highly effective in addressing the client’s wear challenges. The castings’ superior hardness and wear resistance significantly extended the service life of the mining equipment components, reducing downtime and maintenance costs.
The successful implementation of the white iron castings strengthened the partnership between the mining equipment manufacturer and Calmet. The client regarded the firm as a reliable supplier for their ongoing wear-resistant component requirements.
A railway infrastructure company required malleable iron castings for their railway track components, such as rail clips, rail joints, and fastening systems. The client needed materials that offered high tensile strength, ductility, and anti-vibration properties to ensure reliable and safe railway operations.
Calmet recommended malleable iron as the ideal material due to its combination of strength and ductility. Collaborating with the client’s engineering team, they designed and manufactured malleable iron castings tailored to the railway track components’ requirements.
The firm utilized green sand casting techniques and implemented rigorous quality controls to ensure the castings’ dimensional accuracy and mechanical properties. Stringent testing, including tensile strength and impact resistance evaluations, was carried out to verify the castings’ performance under the demanding railway conditions.
The malleable iron castings provided by us proved to be an excellent choice for the railway track components. The castings’ high tensile strength, ductility, and anti-vibration properties ensured reliable and safe railway operations, minimizing the risk of track failures.
The client acknowledged our expertise in malleable iron casting and established a long-term partnership for their railway infrastructure projects. The successful implementation of the castings contributed to the efficient and reliable functioning of the railway system.
To maintain a competitive advantage in the steel casting industry, Calmet always evaluates its unique strengths and value proposition. Here are some factors to consider while analyzing the competitive advantage that Calmet offers:
Sustainable manufacturing focuses on minimizing the environmental impact and maximizing resource efficiency throughout the manufacturing process using the below commonly used techniques:
Innovative technologies can revolutionize the steel casting manufacturing industry, enhancing efficiency, quality, and customization capabilities. Some notable advancements at Calmet include:
The steel-casting manufacturing industry is subject to various regulations, which ensure safety, quality, and environmental compliance. Key regulations include: