Custom Iron Castings
At XDL Machinery, we offer high-quality iron casting services, specializing in gray and ductile iron for various industries. Our advanced casting techniques ensure durable, precision-engineered components that meet the highest standards. With a focus on reliability and performance, we deliver cost-effective solutions tailored to your specific needs, guaranteeing exceptional results every time.
Key Capabilities
At XDL Machinery, we excel in delivering innovative solutions for high-quality iron castings and precision manufacturing. With expertise in mold design and advanced casting techniques, we provide cost-effective solutions tailored to each client’s unique needs. Below is a brief overview of our key capabilities.
1. Pattern Design and Manufacturing
We ensure precision in our pattern design, manufacturing, and sample validation processes. Using advanced CAD software and cutting-edge technologies like CNC machining and 3D printing, we create highly accurate patterns tailored to your specifications. We then validate prototypes through thorough testing for dimensional accuracy, surface finish, and overall quality. This iterative approach ensures that every pattern is refined to perfection, guaranteeing that the final iron casting meets the highest standards of performance and reliability.
2. Commonly Used Material grades
- Gray Iron: HT200, HT250, HT300, HT350
- Ductile Iron: QT400, QT450, QT500, QT600, QT700
Please refer to Material Grades for detailed material data
3. Major Molding Process
We utilize the following key molding processes to deliver high-quality iron castings:
Resin Sand Molding
Uses resin-bonded sand for molds, offering high accuracy and surface finish for medium to large production runs.Lost Foam Molding
Involves a foam pattern that evaporates when molten metal is poured, ideal for complex shapes and thin-walled castings.Shell Molding
Creates detailed castings by forming a thin ceramic shell around a pattern, providing excellent surface finish and dimensional precision.
4. Annual Output
We have the capacity to produce up to 16,000 tons of high-quality iron castings annually. Our advanced facilities and experienced team ensure efficient, large-scale production with consistent precision and on-time delivery.
5. Achievable weight and minimum wall thickness
- Weight Range: 4 kg ~10 Tons.
- Minimum wall thickness: 4mm and above.
6. Precision Tolerances
Casting Tolerances:
Our castings adhere to the standards set by GB/T 6414-2017-DCTG11~13.Machining Tolerances:
We offer machining tolerances as tight as ±0.01 mm, depending on the size and complexity of the product.Best Achievable Surface Roughness:
Castings: Ra 25
Machined surface roughness: Ra 0.8
7. Finishing
We offer a range of surface treatments to enhance both the functionality and appearance of the castings, including:
- Painting
- Powder Coating
- Shot Blasting
- Grinding
- Polishing
- Other Custom Treatments (available upon request)
Iron Casting Process
1. Pattern Making
2. Molding
3. Core Making
4. Coating & Baking
5. Mold Closing
6. Melting
7. Pouring
8. Shakeout & Cleaning
9. Shot Blasting
10. CNC Machining
11. Painting
12. Delivering
gallery of Iron castings
Quality Assurance
At XDL Machinery, we are committed to delivering iron castings of exceptional quality that meet the highest standards in the industry. Our Quality Assurance (QA) processes are designed to ensure precision, consistency, and reliability throughout the entire casting process. We implement advanced techniques and rigorous inspections to meet the specific needs of each project, ensuring the durability and performance of every casting. Our Comprehensive QA Process Includes:
ISO 9001 and IATF 16949 Certified Processes
We exclusively partner with foundries that hold valid ISO 9001 certification, ensuring they adhere to internationally recognized quality management standards. In addition, we conduct thorough annual audits of our partner foundries to verify their compliance and continuously assess their production processes.
Our Comprehensive QA Process Includes:
1. Expert Pattern Design, Manufacturing & Sample Validation
Years of experience in pattern design and manufacturing enables us to enure every iron casting project begins with the highest level of precision. Using advanced CAD software and cutting-edge technologies such as CNC machining and 3D printing, our expert team creates accurate, durable patterns tailored to your specifications. Before mass production, we validate each pattern through sample castings, conducting thorough inspections for dimensional accuracy, surface finish, and overall quality.
2. Carbon-Silicon Analysis
We use Carbon-Silicon Analyzer to assess the properties of molten metal before pouring it into molds. This process involves testing key factors such as temperature, composition, and chemical balance to prevent defects like shrinkage, porosity, or inclusions in the final product. By using cutting-edge technologies and analytical methods, we ensure the molten metal meets precise specifications, optimizing the casting’s structural integrity and performance.
3. Metallographic Testing (Spheroidization Rate Testing)
We ensure the highest quality by conducting Metallographic Testing, including Spheroidization Rate Testing, to assess the microstructure and uniformity of our castings. This testing helps us verify the distribution of graphite within cast iron, which is crucial for optimizing material strength, machinability, and overall performance.
4. Spectrometer (Chemical Properties Analysis)
We use a spectrometer to precisely analyze the chemical composition of the test bars, ensuring they meet the specified material requirements.
5. Mechanical Properties Testing
We conduct comprehensive mechanical property testing on test specimens to ensure our iron castings meet the required performance standards. We utilize a range of advanced methods to guarantee the integrity and reliability of every casting:
- Yield Strength Testing: We perform yield strength tests to determine the stress at which the material will begin to deform permanently, ensuring the casting can handle operational loads without failure.
- Tensile Strength Testing: Tensile strength tests are conducted to evaluate the tensile strength and elongation properties of the material, ensuring it can withstand the stresses it will encounter during use.
- Hardness Testing: We perform hardness tests to determine the resistance of the material to wear, indentation, and deformation, ensuring durability in demanding applications.
- Impact Testing: Using an impact tester, we assess the material’s toughness, ensuring that it can absorb energy without fracturing, even under sudden stress or impact.
5. Dimensional Inspection Methods
At XDL Machinery, we utilize a variety of precise dimensional inspection methods to ensure that every casting meets the required specifications and tolerances. Our extensive inspection process involves both advanced digital equipment and traditional measuring tools, providing an accurate and comprehensive evaluation of each product’s dimensions. Those tools include Faro Portable Measurement Arms, Vernier Calipers, Micrometers, Dial Indicators, Thread Gauges, etc.
5. Tightness and Pressure Testing
To ensure that our castings meet stringent quality standards, we conduct a variety of pressure tests in accordance with customer specifications, including the following:
Air Tightness Test: We conduct air tightness tests to detect any potential leaks or gaps in the casting. This is particularly important for components that need to maintain pressure without losing air, such as valves, pipes, or sealed housings. The test ensures the casting can withstand air pressure without compromising performance.
Water Tightness Test: Similar to the air tightness test, the water tightness test is performed to assess the ability of a casting to hold water without leaks. This test is especially crucial for applications involving fluid flow, such as pumps, tanks, and hydraulic systems, where water integrity is essential for optimal operation.
6. Non-Destructive Testing (NDT)
To ensure the structural integrity and reliability of our iron castings, XDL Machinery employs a range of Non-Destructive Testing (NDT) methods, including Penetrant Testing (PT), Magnetic Particle Testing (MT), and Ultrasonic Testing (UT). These methods allow us to detect internal and surface defects without damaging the casting.
Penetrant Testing (PT): We use PT to identify surface cracks, porosity, or other flaws. This test involves applying a colored or fluorescent dye to the surface and examining it for any signs of leakage, ensuring a flawless surface finish.
Magnetic Particle Testing (MT): For ferromagnetic materials, MT is used to detect surface and subsurface defects. By applying a magnetic field to the casting and using fine magnetic particles, we can identify any cracks or discontinuities that could affect the casting’s strength.
Ultrasonic Testing (UT): UT is employed to detect internal defects such as voids, cracks, and porosity. High-frequency sound waves are transmitted through the material, and any irregularities in the waves’ return provide valuable insights into the casting’s internal structure.
7. Traceability and Documentation
AtXDL Machinery, we ensure traceability and comprehensive documentation for every iron casting we produce. Each casting is assigned a unique serial number, which is engraved, stamped, or laser-etched onto the product. This serial number enables us to trace every casting back to its specific production batch, ensuring full traceability throughout its lifecycle.
We also maintain detailed documentation for each project, including mill certificates, inspection reports, and any third-party inspection reports. This ensures complete transparency and allows us to provide customers with the necessary records to verify the quality and compliance of their castings, reinforcing our commitment to consistent and reliable performance.
At XDL Machinery, our rigorous Quality Assurance processes—from material selection to final inspection-ensure that every iron casting meets the highest standards of precision, durability, and performance. Through advanced testing and expert oversight, we deliver products you can trust, every time.
Materials
Materials Used in Iron Casting
Various types of iron are used in casting processes, depending on the required mechanical properties, durability, and application. Here are the main types of iron commonly used in casting.
Gray Cast Iron
- Gray cast iron is widely used due to its excellent machinability, good vibration damping, and cost-effectiveness. It has a graphite flake structure, which contributes to its high thermal conductivity and compressive strength.
- Gray cast iron is commonly used in engine blocks, machine bases, and pipes.
| China | USA | Japan | UK | Germany | ISO |
|---|---|---|---|---|---|
| GB/T 9439 | ASTM A48 | JIS G5501 | BS 1452 | DIN 1691 | ISO 185 |
| HT350 | Class60 | FC350 | Grade350 | GG35 | JL350 |
| HT300 | Class50 | FC300 | Grade300 | GG30 | JL300 |
| HT250 | Class40 | FC250 | Grade250 | GG25 | JL250 |
| HT200 | Class30 | FC200 | Grade200 | GG20 | JL200 |
| HT150 | Class20 | FC150 | Grade150 | GG15 | JL150 |
| HT100 | Class10 | – | – | GG10 | JL100 |
Ductile Iron
- Ductile iron, also known as nodular cast iron, contains spheroidal graphite, giving it superior ductility and toughness compared to gray iron.
- Ductile iron is often used in automotive components, gears, and pressure pipes. Ductile iron provides excellent wear resistance and fatigue strength, making it ideal for load-bearing applications. bases, and pipes.
| China | USA | Japan | UK | Germany | ISO |
|---|---|---|---|---|---|
| GB/T 1348 | ASTM A536 | JIS G5502 | BS EN 1563 | DIN 1693 | ISO 1083 |
| QT400-18 | 60-40-18 | FCD400-18 | EN-GJS-400-18 | GGG40 | GS-400-18 |
| QT450-10 | 65-45-12 | FCD450-10 | EN-GJS-450-10 | – | GS-450-10 |
| QT500-7 | 70-50-05 | FCD500-7 | EN-GJS-500-7 | GGG50 | GS-500-7 |
| QT600-3 | 80-60-03 | FCD600-3 | EN-GJS-600-3 | GGG60 | GS-600-3 |
| QT700-2 | 100-70-3 | FCD700-2 | EN-GJS-700-2 | GGG70 | GS-700-2 |
| QT800-2 | 120-90-02 | FCD800-2 | EN-GJS-800-2 | GGG80 | GS-800-2 |
Success Stories with our Clients
In 2013, we were honored to receive a certificate of appreciation from our clients. This accolade recognized our flawless track record of zero defects and no delivery delays over ten years, underscoring our dedication to providing reliable and high-quality service that our clients can depend on.
At XDL Machinery, we are steadfast in our commitment to excellence. We will continue to leverage our expertise to deliver superior products, tailored to meet the unique requirements of each client. Our promise is to offer meticulous and attentive service, ensuring that every client experiences the utmost satisfaction and peace of mind.
Industries We Serve
we have extensive experience serving a wide range of industries, providing high-quality iron castings tailored to their unique needs. Our products have been trusted by leaders in the following sectors
- Industrial Equipment
- Pumps
- Motors & Engines
- Construction Machinery
- Metallurgical Industry
- Shipbuilding Components
FAQs: Your Queries Answered
A: Our main casting processes include:
- Resin Sand Molding
- Lost Foam Molding
- Shell Molding.
A: The following materia and grades are the most common ones we cast:
- Gray Iron: HT200, HT250, HT300, HT350, etc.
- Ductile Iron: QT400, QT450, QT500, QT600, QT700, etc.
A: The lifespan of our molds varies depending on the specific product. Typically, the lifespan is as follows:
- Wooden molds: 0.5 to 1 year
- Aluminum alloy molds: 8 to 10 years or 100,000 to 1,000,000 parts
- FRP molds: 5 to 10 years
- PVC molds: 3 years
A: Depending on the size and complexity of the product, it typically takes 1 to 3 months.
A: Before starting production of a product in a foundry, it is essential to “develop the casting process,” which is crucial for ensuring product quality and production efficiency. The process of developing the casting process typically includes the following main steps:
- Analysis and Optimization of Castings’ Structure and Castability: Analyzing the structure of the casting, evaluating its castability, and making necessary optimizations to reduce casting defects and improve production efficiency.
- Determination of Casting Process Parameters: This includes determining parameters such as machining allowance, parting line number, and process correction allowances. These parameters are crucial for controlling the dimensional accuracy and quality of the casting.
- Design of the Gating System: Designing the channels that guide the molten metal into the mold cavity. This has a significant impact on the casting’s quality, so it is necessary to carefully select the type of gating system, the position of the inner gate, and the cross-sectional dimensions of each component.
- Design of Risers: Properly designing the risers and compensations to offset the shrinkage of the liquid and solidified metal during cooling, ensuring the integrity of the casting.
- Design of Chills: Using chills to control the solidification process of the casting, improving the internal quality and mechanical properties of the casting.
- Determination of Pouring Temperature, Pouring Speed, and Pouring Time: These parameters have a direct impact on the casting’s quality and production efficiency, and they need to be precisely controlled based on the casting’s material and structure.
- Production Preparation: This includes preparing materials for melting, molding and core-making materials, patterns, core boxes, sandboxes, and other process equipment.
A: The common casting defects and our methods for preventing them are as follows:
• Slag Inclusion: Slag from the molten metal is trapped in the casting, causing defects.
◦ Solution: Prevent slag inclusion by installing ceramic filters in the gating system to effectively filter out slag and impurities before pouring the metal into the mold.
• Sand Inclusion: Sand particles from the mold are embedded in the casting, resulting in surface defects.
◦ Solution: Minimize the risk of sand inclusion by ensuring that the mold and core are properly cleaned. When closing the mold, avoid scraping or damaging the sand core. Always clean the gating system and the mold thoroughly before pouring to remove any loose sand or debris.
• Porosity: Gas pockets or voids form within the casting due to trapped air or gases.
◦ Solution: To reduce porosity, control the quality of the furnace charge, ensure thorough core baking, and develop a rational gating system. Adjust pouring temperature and venting plans according to the casting’s structure to allow gases to escape.
• Shrinkage Cavity: A shrinkage cavity is a large void that forms due to the metal’s contraction during cooling. It typically occurs in the last areas to solidify, often leaving a significant cavity.
◦ Solution: To avoid shrinkage cavities, use the proper chemical composition in the molten metal, control the pouring temperature, and optimize the gating and riser systems. Adequate feeding systems ensure the metal fills the last solidifying areas, preventing voids from forming.
• Shrinkage Porosity: Shrinkage porosity refers to small voids that form throughout the casting as a result of the metal shrinking during cooling and solidifying. Unlike shrinkage cavities, the pores are smaller and often scattered inside the casting.
◦ Solution: Prevent shrinkage porosity by adjusting the pouring temperature and using the correct alloy composition to promote uniform solidification. Position risers and feeders properly to ensure the metal has a continuous supply as it cools, preventing void formation.
• Looseness: Looseness is a type of internal porosity caused by an irregular solidification process. It leads to weak or porous areas within the casting, reducing its strength and density.
◦ Solution: To reduce looseness, control the pouring temperature and solidification rate. Properly designed gating systems ensure the metal fills the mold uniformly, while using suitable mold materials helps regulate cooling and solidification to prevent porosity.
• Cold Shut: Occurs when two streams of molten metal meet but fail to fuse properly, leaving a weak or incomplete spot in the casting.
◦ Solution: Use a rational gating system and adjust pouring temperature based on material and wall thickness requirements to ensure proper fusion of the metal streams.
• Lack of Material: Missing material or incomplete sections due to improper mold filling.
◦ Solution: Before casting, check the mold for integrity and ensure no defects. Properly compact the sand and ensure the mold’s strength. Carefully check the core for excess sand or debris before assembly. Ensure a proper pouring speed, and avoid mold damage during boxing, cleaning, or grinding to prevent physical impact to the casting.
• Mold Swelling: Mold material swells due to moisture or thermal expansion, which can distort the casting shape.
◦ Solution: Select the correct sand box size according to the casting’s dimensions, choose appropriate steel plate thickness for the box to ensure strength, and compact the sand tightly to maintain mold integrity. After assembling the mold, make sure all fasteners are securely tightened to prevent any expansion.
• Sand Burn-On: Sand adheres to the surface of the casting, causing rough texture or surface contamination.
◦ Solution: Ensure cores are compacted properly in areas prone to sand adhesion. Use high-quality refractory materials and apply coatings carefully to ensure even coverage. Ensure the correct coating thickness and avoid over-spraying.
• Deformation: Castings may warp or distort due to internal stresses from uneven cooling or improper handling.
◦ Solution: Inspect the mold for deformation before casting. Ensure the mold’s base is fully in contact with the ground, and use wedges to secure it. Strictly control the resin sand curing time, and ensure proper contact with the ground to avoid suspended sections. Follow the recommended box-assembly time for different castings to prevent warping.
• Insufficient Pouring: The casting does not receive enough molten metal, leading to incomplete filling.
◦ Solution: Consider the weight of the product when designing the gating system, and select the appropriate pouring temperature and speed. After filling the mold, ensure that additional molten metal is added to compensate for shrinkage and maintain full metal flow to the mold.
A: The typical tolerances for iron castings vary depending on the casting method, part size, and precision requirements. Here in XDL, the tolerance range for our iron castings could be from DCTG11 to DCTG13, according to ISO 8062-3 / (the Chinese equivalient is GB/T 6414) .
A: Yes,
- We prioritize sustainability. Iron is a recyclable material, and we minimize waste during the casting process to reduce our environmental impact.
- We use specialized equipment to treat harmful gases and dust generated during melting, ensuring compliance with national emission standards.
A: We can provide the following surface treatments:
- Grinding,
- sandblasting
- polishing
- painting, coating
or as per customer requirements.
A: Yes, we have the capability to design and manufacture molds. Typically, we provide aluminum alloy or wooden patterns. Depending on the actual requirements, we can also produce FRP (fiberglass reinforced plastic) and PVC patterns.
