Ductile Iron Casting

Looking for iron castings manufacturer? We are your trusted partner in the realm of ductile iron casting. With over two decades of expertise in the metal casting industry, we take pride in delivering top-notch precision and quality in every aspect . As a reliable leader in casting suppliers, we excel in producing high-quality ductile iron castings that meet the diverse needs of our valued customers. 

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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:

  1. 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. 

  2. 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.

  3. 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.

Shell Molding Casting

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_Furnace

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.

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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.

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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)
60-40-18414≥400≥400276170-2297.0
65-45-12448≥450≥450310187-24110.0
80-55-06552≥500≥500379217-26915.0
100-70-03689≥600≥600483255-30225.0
120-90-02827≥700≥700621302-36335.0
140-110-01965≥800≥800689341-44445.0
160-135-041103≥900≥900758400-51250.0

Samples of Ductile Iron Castings

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The Advantages of Ductile Iron Casting

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 Good Mechanical Properties

With its remarkable flexibility and resilience to fluctuating temperatures, ductile iron casting stands as a highly versatile material, ensuring reliable performance under varying loads and environmental challenges.

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Superior Corrosion Resistance

Ductile iron casting showcases commendable resistance to both corrosion and oxidation, thus ensuring its longevity even when subjected to humid, corrosive, or chemically active environmental conditions. This innate durability makes it a reliable choice for a wide array of applications, capable of withstanding challenging settings and maintaining its structural integrity over an extended operational lifespan.

Precision in Manufacturing and Complex Shapes

Ductile iron casting boasts the unique ability to be intricately cast into complex geometrical shapes, minimizing the necessity for additional machining processes. This inherent feature significantly enhances manufacturing efficiency, offering a cost-effective solution that aligns with intricate design requirements, streamlining the production process and ultimately delivering superior results.

Excellent Lubrication Characteristics

The inherently smooth surface of ductile iron casting not only reduces friction but also significantly boosts the wear resistance of components. This advantageous feature ensures a prolonged operational lifespan, making it a preferred material choice for components subjected to demanding wear conditions.

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.