We represent both jobbing and production sand cast iron foundries that use both match plate and cope and drag patterns.
We have 36,000 square feet of production space and currently employ 46 people.
Our convenient location allows us to be serviced by all major freight carriers. We also provide direct local delivery services, in most circumstances.
Our typical iron grades are Ductile 65-45-12 and 80-55-06, and Gray Iron Classes 20, 30, 35 and 40, though other grades are available on a case-by-case basis. Our typical casting weights range from 1 ounce to 500 pounds.
Our molding facilities consist of a Roberts-Sinto FBO III automatic molding machine capable of 20×24 tooling. Adapter plates for off-sized tooling is available. Three squeezer lines with flask sizes ranging from 13×13 through 20×20. We also operate one Cope and Drag Floor mold line with flask sizes ranging from 24×24 through 30×30.
A Beardsley and Piper 85B Speed Muller supplies the green sand for the Sinto. The sand is tested for quality by a Hartley sand control system. Additionally, an International Molding Machine automatic mold handler handles our molds. Castings are cleaned in a Didion Rotary Drum Media Cleaner and finished in a Wheelabrator Short Blast Cleaner. We have stand grinders for most parts, and table grinders for larger parts.
Melting facilities consist of two Inductotherm induction furnaces. PC-based chemistry testing is done in-house with outside independent evaluation done daily on ductile chemistry and physical properties to ensure compliance to published standards. Certifications are available upon request.
To meet your machining needs, we have a shop utilizing the latest CNC equipment, as well as conventional machining equipment.
We also have the ability of outside tooling and plating, if the need arises.
Give us a call. We would like to have an opportunity to establish a relationship with your company.
36,000 square feet of production floor space
Molding 1 Roberts-Sinto FBO III Automatic Molding Machine (20×24)
3 BMM Green Sand Squeezer Lines (13×13 through 20×20)
Cope and Drag Green Sand Line (up to 60×60 in)
Palmer M200 Air Set Molding Machine (13×13 through 60×60)
Sand Equipment 1 Simpson Sand Muller (5 Tons per Hour)
1 Beardley and Piper Model 85B (40 Tons per Hour)
1 Hartley Automatic Sand Controller Unit
Core Equipment Shell Core
Oil Sand Production with 2 gas-fired core ovens
Air Set (Chemical Bond)
Melting 1 Inductotherm VIP 500 Kilowatt Furnace
1 Inductotherm VIP 750 Kilowatt Furnace
1 Foundry Information Systems Melt Lab
Cleaning 1 Didion MD-50 Rotary Drum Media Cleaner
1 Wheelabrator Shot Blast Cleaner
8 – 20 inch Stand Grinders
• Clausing Engine 15″OD
• Wasino LJ-5 1.5″ collet & 8″ chuck, maximum capacity 9″OD x 18″Z
• Wasino LJ-6 10″ chuck, maximum capacity 19″OD x 23″Z
• Amier Seiki TC-4L 10″ chuck,
maximum capacity 14″OD x 24″Z
CNC Milling Centers
• Hitachi Seiki Horizontal HC400 w/pallet changers, pallet size 17″ x 17″ x 17″
• Hitachi Seiki Vertical VA-45 maximum travel 28″X x 18″Y x 18″Z
• Fadal 3016 30″X x 16″Y x 24″Z
• Haas Indexing Head attachment with CNC controls & 12″ diameter capacity
• Brother CNC Drill & Tap Machine,
16″X x 12″Y x 10″Z
Coordinate Measuring Machine
• Browne & Sharpe Reflex
• 3 – Bridgeport milling machines
with NC controls
• 2 – Hand mills
• Cincinnati Horizontal Mill
• 2 – 6-line Walker Turner 15″
• 1 – 5-line Clausing 15″
• 1 – 4-line Clausing 10″
• 2 – 4-line Walker Turner 10″
• 6 – Single spindle
• K O Lee, 6 x 12 chuck
• K O Lee
• Cutter Master (Baldor Diamond)
Cut Off Saws
• Johnson Horizontal
• Power Matic Vertical
• Scotchman Cold Saw 12″ for
Brass & Aluminum
|Iron castings are produced by a variety of molding methods and are available with a wide range of properties. Cast Iron is a generic term that designates a family of metals. The six types of cast iron are gray iron, ductile iron, compacted graphite iron (CGI), malleable iron, white iron and alloyed iron.
The basic strength and hardness of all iron alloys is provided by the metallic structures containing graphite. The properties of the iron matrix can range from those of soft, low-carbon steel (18 ksi/124 MPa) to those of hardened, high-carbon steel (230 ksi/1,586 MPa). The modulus of elasticity varies with the class of iron, shape (sphericity) and volume fraction of the graphite phase (percent free carbon).
Because of their relatively high silicon content, cast irons inherently resist oxidation and corrosion by developing a tightly adhering oxide and subscale to repel further attack. Iron castings are used in applications where this resistance provides long life. Resistance to heat, oxidation and corrosion are appreciably enhanced with alloyed irons.
Properties of the cast iron family can be adjusted over a wide range and enhanced by heat treatment. Annealing readily produces a matrix of soft machinable ferrite. In limited situations, this annealing can be accomplished at sub-critical temperatures. Heating above this critical temperature takes the carbon from the graphite and places it in the matrix. This engineered material can be through-hardened and tempered using conventional heat treating or surface hardening. These adjustments create the different members of the cast iron family.
Gray iron—Flake graphite provides gray iron with unique properties (such as excellent machinability) at hardness levels that produce superior wear-resistant characteristics, the ability to resist galling and excellent vibration damping.
Ductile iron—An unusual combination of properties is obtained in ductile iron because the graphite occurs as spheroids rather than as flakes. The different grades are produced by controlling the matrix structure around the graphite either as-cast or by heat treatment. Only minor compositional differences (to promote the desired matrix microstructure) exist among the regular grades. Alloy additions may be made to assist in controlling the matrix structure as-cast or to provide response to heat treatment.
The high-strength grades can be quenched and tempered to form a bainite-like matrix produced by austempering. Austempered ductile iron (ADI) provides twice the strength of conventional ductile iron at a given level of ductility. ADI can have strength in excess of 230 ksi (1,586 MPa); however, its modulus is 20% lower than steel with a comparable strength.
Compacted Graphite Iron (CGI)—In CGI, graphite locally occurs as interconnected blunt flakes. This graphite structure and the resulting properties are intermediate between gray and ductile irons. The compacted graphite shape also is called quasi-flake, aggregated flake, semi-nodular and vermicular graphite.
White iron—White iron is hard and essentially free of graphite. The metal solidifies with a compound called cementite, which is a phase that dominates the microstructure and properties of white iron. The carbides are in a matrix that may be pearlitic, ferritic, austenitic, martensitic or any combination thereof.
Malleable iron—In malleable iron, the graphite occurs as irregularly shaped nodules called temper carbon because it is formed in the solid state during heat treatment. The iron is cast as a white iron of a suitable chemical composition to respond to the malleabilizing heat treatment.
Alloyed iron—This classification includes gray irons, ductile irons and white irons that have more than 3% alloying elements (nickel, chromium, molybdenum, silicon or copper). Malleable irons are not heavily alloyed because many of the alloying elements interfere with the graphite-forming process that occurs during heat treatment.
There are no generally accepted standards for the surface finish, machining allowances or dimensional tolerances. Although some production metalcasting facilities have established guidelines for their own capability in dimensional control, these controls are typically established through concurrent engineering based on the requirements of the application.
Material Properties vs. Casting Processes
Types of Specifications
Ductile iron has some variation in properties when not heat treated; however, a single size test bar generally is satisfactory (except for large castings). Malleable iron is not poured into heavy sections, and because all malleable iron castings are heat treated, a single size test bar will work. For some applications, the finished component is tested in the manner in which it will be used. For example, pressure-containing parts can be 100% hydraulically proof tested.
The acceptance of the castings is based on characteristics that a metalcasting facility can evaluate and control during production. Some specifications limit the amount of certain elements because they can affect properties or characteristics of the iron that are not readily apparent or measured. For example, the alloy content of iron can influence its corrosion resistance or its properties at elevated temperatures. With the exceptions of castings that have special performance applications, such as use at elevated temperatures, the most economical approach is to let the metalcasting facility recommend an iron composition that provides the desired properties.
Gray Iron Properties
Gray iron’s compressive strength is typically three to four times more than its tensile strength. The lack of graphite-associated volume changes allows for a similar Poisson’s ratio to other engineering metals but different tension properties. Poisson’s ratio remains constant at 0.25 over a large compressive stress range and increases at higher stress levels.
To classify gray iron in accordance to its tensile strength, ASTM Standard A48 and Society of Automotive Engineers (SAE) Standard J431 provide the best details. The two specifications approach the task from different standpoints, but the concept essentially remains the same. For example, the number in a Class 30 gray iron refers to the minimum tensile strength in ksi. In ASTM A48, a standard size test bar is added to the class. Class 30A indicates that the iron must have a minimum 30 ksi (207 MPa) tensile strength in an “A” bar (0.875-in. as-cast diameter).
In SAE Standard J431, tensile strength is not required, but hardness and a minimum tensile strength to hardness ratio are required. The class then is identified as a grade. A Class 30B iron for ASTM A48 would be comparable to a grade G3000 in SAE Standard J431. The other gray iron specifications build off of these two primary specifications.
Ductile Iron Properties
The development and commercialization of ADI provides design engineers with a new group of cast ferrous materials. Austempering at higher temperatures produces ADI with lower strength and hardness as well as higher ductility and toughness.
In regards to heat treatment, it has been found that quenching certain troublesome parts in hot media (more than 450F/230C) resulted in tougher parts with less distortion than those conventionally quenched and tempered. These materials offer mechanical properties that are stronger and tougher than conventionally heat treated, as-cast or as-formed ferrous materials. The property combinations available for ADI list five standard grades in ASTM A897. These specifications give the minimum tensile and impact levels along with typical Brinell hardness values.
Compared to the best forged steel, ASTM 897 Grade 5 ADI Charpy V-notch impact toughness is low, but the fracture toughness is approximately equal. Ausferrite microstructures respond to shot peening, fillet rolling and grinding and lead to an increase in bending fatigue strength with favorable compressive residual stresses impacted on the surfaces.
The grades of CGI are 250, 300, 350, 400 and 450, based on their tensile strength. The lowest strength is ferritic, and the highest strength is pearlitic. Although considerable range exists, relative damping capacities among gray iron, CGI and ductile iron are 1.0, 0.35 and 0.14. The damping capacity is independent of carbon and pearlite content for all practical CGI compositions. The damping capacity can be increased 5–10% by increasing the coarseness of graphite; however, this will decrease the modulus.
White Iron & Alloyed Iron Properties
Nickel alloyed austenitic irons are a well-established group of the high-alloy austenitic irons (commonly known as Ni-Resist) that are produced for corrosion-resistant applications. These versatile irons have excellent corrosion resistance due to the presence of nickel (12–37%), chromium (0.5–6%) and copper (5.5–7.5%). Most of the Ni-Resist compositions can be produced as either gray or ductile iron.
The chromium-bearing ductile irons D-2 and D-5B, and the high-silicon Type D-5S, provide good oxidation resistance and useful mechanical properties at temperatures up to 1,400F (760C). At higher temperatures, D-2B, D-3, D-4 and D-5S have useful properties, and D-5S has good oxidation resistance up to 1,700F (925C). The high-nickel austenitic irons are metallurgically stable over their useful temperature range, experience no phase changes and are resistant to warping, distortion, cracking and growth during thermal cycling.
Malleable Iron Properties
Machining Cast Iron
Coating & Surface Engineering
Design Range of Properties
Ductile iron—Ductile iron has the ability to be used as-cast and without heat treatments or other further refining. It has a tensile strength comparable to many steel alloys and a modulus of elasticity between that of gray iron and steel. As its name implies, it has a high degree of ductility. It can be cast in a wide range of casting sizes and section thickness; however, thinner sections may require annealing to obtain a high ductility. Alloy additions may be needed to obtain the higher-strength grades in heavy sections.
CGI—CGI has benefits in tensile strength, stiffness, fatigue behavior and strength-to-weight ratios for moderately thin and medium section castings compared to other irons.
White iron—This iron is unique in that it is the only member of the cast iron family in which carbon is present only as a carbide. The presence of different carbides, depending on the alloy content, makes white iron hard and abrasion-resistant but also very brittle.
Malleable iron—Malleable iron is ideal for thin-sectioned components that require ductility. Ferritic malleable iron is produced to a lower strength range than pearlitic malleable iron but with higher ductility. It is the most machinable of cast irons, and it can be die-strengthened or coined to bring key dimensions to close tolerance limits. However, ductile iron is replacing malleable iron in many different applications because the engineering properties of ductile iron are almost identical to that of malleable iron, and ductile iron does not require extensive heat treatment to precipitate graphite.
Alloyed irons—These irons are classified as two types: corrosion-resistant and elevated-temperature service. Corrosion-resistant alloyed cast iron is used to produce parts for engineering applications that operate in an environment such as sea water, sour well oils, commercial organic and inorganic acids and alkalis. Elevated-temperature service alloyed iron resists formation and fracture under service loads, oxidation by the ambient atmosphere, growth and instability in structure up to 1,100F (600C). The ability to cast complex shapes and machine alloyed irons makes them an attractive material for the production of components in chemical processing plants, petroleum refining, food handling and marine service.
–The American Foundry Society Technical Dept. and George M. Goodrich, Professional Metallurgical Services