Carbon Steel Castings

Dandong Dawang Steel Castings Co., Ltd. can produce different types of carbon steel castings. Carbon steel has high strength, high hardness, high toughness and low cost. It is mainly used in construction machinery, auto parts, coal mining machinery, lifting machinery, railway locomotives and ship parts, etc.

the technology

Carbon 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.

the technology

Carbon 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.

Questions about carbon steel casting service

Carbon steel is an iron – carbon alloy with a carbon content of 0.0218% to 2.11%. Cast iron generally has a carbon content of 2.5% to 3.5%. Carbon steel has relatively good strength and toughness and is used to manufacture various mechanical parts and metal products. The properties of cast iron are lower than steel, especially the tensile strength and plasticity are low, and it cannot be forged, but its hardness and compressive strength are better.

The characteristic of carbon steel is that the hardness can be adjusted by heat treatment as required. The disadvantage is that it is easy to rust in the daily environment. The characteristic of stainless steel is that the material will not rust in the daily environment. The disadvantage is that its hardness can only be annealed but not quenched by heat treatment.

1. Gas Porosity
The reason for the pores is that there is too much water in the molding material or a lot of gas – producing substances; the air permeability of molding sand and core sand is poor; the pouring speed is too fast.
2. Trachoma
The causes of blisters include insufficient molding sand strength; insufficient molding sand compactness; and too fast pouring speed.
3. Shrinkage
The cause of shrinkage cavity is poor feeding of the casting during solidification.
4. Sticky sand
The cause of sticky sand is the poor fire resistance of the molding sand or the high pouring temperature.
5. Cracks
The causes of the cracks are the large difference in the wall thickness of the castings; the improper setting of the gating system; the new difference between the sand mold and the core.

Carbon Steel is divided into three subgroups depending on the amount of carbon in the metal: Low Carbon Steels/Mild Steels (up to 0.3% carbon), Medium Carbon Steels (0.3–0.6% carbon), and High Carbon Steels (more than 0.6% carbon).

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