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Castings of Stainless Steel, Alloy & Carbon Steel, Cast Iron, etc.

Grey Cast Iron Shell Casting Product

Short Description:

Casting Metals: Grey Cast Iron, GG20 / GG25, EN-GJL-200 / EN-GJL-250

Casting Manufacturing: Resin Coated Shell Mold Casting

Weight: 18.50 kg

Surface Treatment: Customized

Heat Treatment: Annealing, Quenching + Tempering

 

Custom grey cast iron casting product by shell mould casting and CNC machining. Our sand casting foundry can design custom castings of diverse of cast irons in cooperation with customers to optimize the casting costs by applying suitable casting technologies and developing the best engineering solutions with respect to the usability features of the final castings. 


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Custom grey cast iron shell mold casting products with services of CNC machining, heat treatment and surface treatment. 

Gray iron, or grey cast iron, is a type of cast iron that has a graphite microstructure. It is named after the gray color of the fracture it forms. The gray cast iron is used for housings where the stiffness of the component is more important than its tensile strength, such as internal combustion engine cylinder blocks, pump housings, valve bodies, electrical boxes, counter weights and decorative castings. Grey cast iron's high thermal conductivity and specific head capacity are often exploited to make cast iron cookware and disc brake rotors.

A typical chemical composition to obtain a graphitic microstructure is 2.5 to 4.0% carbon and 1 to 3% silicon by weight. Graphite may occupy 6 to 10% of the volume of grey iron. Silicon is important to making grey iron as opposed to white cast iron, because silicon is a graphite stabilizing element in cast iron, which means it helps the alloy produce graphite instead of iron carbides; at 3% silicon almost no carbon is held in chemical combination with the iron.

The graphite takes on the shape of a three-dimensional flake. In two dimensions, as a polished surface will appear under a microscope, the graphite flakes appear as fine lines. The tips of the flakes act as preexisting notches; therefore, it is brittle. The presence of graphite flakes makes the Grey Iron easily machinable as they tend to crack easily across the graphite flakes. Grey iron also has very good damping capacity and hence it is mostly used as the base for machine tool mountings.

 

Mechanical Properties of Gray Cast Iron

Item according to DIN EN 1561 Measure Unit EN-GJL-150 EN-GJL-200 EN-GJL-250 EN-GJL-300 EN-GJL-350
EN-JL 1020 EN-JL 1030 EN-JL 1040 EN-JL 1050 EN-JL 1060
Tensile Strength Rm MPA 150-250 200-300 250-350 300-400 350-450
0.1% Yield Strength Rp0,1 MPA 98-165 130-195 165-228 195-260 228-285
Elongation Strength A % 0,3 – 0,8 0,3 – 0,8 0,3 – 0,8 0,3 – 0,8 0,3 – 0,8
Compressive Strength σdB MPa 600 720 840 960 1080
0,1% Compressive Strength σd0,1 MPa 195 260 325 390 455
Flexural Strength σbB MPa 250 290 340 390 490
Schuifspanning σaB MPa 170 230 290 345 400
Shear Stress TtB MPa 170 230 290 345 400
Modules of elasticity E GPa 78 – 103 88 – 113 103 – 118 108 – 137 123 – 143
Poisson number v 0,26 0,26 0,26 0,26 0,26
Brinell hardness   HB 160 – 190 180 – 220 190 – 230 200 – 240 210 – 250
Ductility σbW MPa 70 90 120 140 145
Tension and pressure change σzdW MPa 40 50 60 75 85
Breaking Strength Klc N/mm3/2 320 400 480 560 650
Density   g/cm3 7,10 7,15 7,20 7,25 7,30

 

cast iron shell casting foundry

 

Shell molding casting process is also called pre-coated resin sand casting process, hot shell molding castings or core casting process. The main molding material is the pre-coated phenolic resin sand, which is more expensive than green sand and furan resin sand. Moreover, this sand can not be recycle used. 

Furan resin self-hardening sand casting process (nobake process) uses the furan resin coated sand to form the casting mold. After mixing the original sand (or reclaimed sand), liquid furan resin and liquid catalyst evenly, and filling them into the core box (or sand box), and then tighten it to harden into a mold or mold in the core box (or sand box) at room temperature. Then the casting mould or casting core were formed, which is called self-hardening cold-core box molding (core), or self-hardening method (core).

Because the mold is formed at room temperature and no need to heat, the self-hardening sand casting is also called no-bake casting process. The self-hardening method can be divided into acid-catalyzed furan resin and phenolic resin sand self-hardening method, urethane resin sand self-hardening method and phenolic monoester self-hardening method.

As a self-hardening cold box binder sand, furan resin sand is the earliest and currently most widely used synthetic binder sand in Chinese foundry. The amount of resin added in molding sand is generally 0.7% to 1.0%, and the amount of added resin in core sand is generally 0.9% to 1.1%. The content of free aldehyde in furan resin is below 0.3%, and some factories have dropped to below 0.1%. In the foundries in China, the furan resin self-hardening sand has reached the international level regardless of the production process and the surface quality of the castings.

Equivalent Grade of Grey Cast Iron

AISI W-stoff DIN BS SS AFNOR U.N.E. / I.H.A. JIS UNI
A48-20B 0.6010 GG-10 Grade 100 0110-00 - - FC 100 G 10
A48-25B 0.6015 GG-15 Grade 150 0115-00 Ft 15 D FG 15 FC 150 G 15
A48-30B 0.6020 GG-20 Grade 200 0120-00 Ft 20 D FG 20 FC 200 G 20
A48-40B 0.6025 GG-25 Grade 250 0125-00 Ft 25 D FG 25 FC 250 G 25
A48-45B 0.6030 GG-30 Grade 300 0130-00 Ft 30 D FG 30 FC 300 G 30
A48-50B 0.6035 GG-35 Grade 350 0135-00 Ft 35 D FG 35 FC 350 G 35
A48-60B 0.6040 GG-40 Grade 400 0140-00 Ft 40 D - FC 40 -
32510   GTS-35 B340/12 0815-00 MN 35-10 - FCMW 330 -
A220-40010 0.8145 GTS-45 P440/7 0852-00 MN 450 - FCMP 440/490 GMN 45
A220-50005 0.8155 GTS-55-04 P510/4 0854-00 MP 50-5 - FCMP 490 GMN 55
A220-70003 0.8165 GTS-65-02 P570/3 0856-00 MN 650-3 - FCMP 590 GMN 65
A220-70003 - GTS-65 P570/3 0858 MN 60-3 - FCMP 540 -
A220-80002 0.8170 GTS-70-02 P690/2 0862-00 MN 700-2 - FCMP 690 GMN 70

 

Microstructure of Gray Iron

 

Resin Coated Sand Casting Metal and Alloys

Metal & Alloys Popular Grade
Gray Cast Iron GG10~GG40; GJL-100 ~ GJL-350; 
Ductile (Nodular) Cast Iron GGG40 ~ GGG80; GJS-400-18, GJS-40-15, GJS-450-10, GJS-500-7, GJS-600-3, GJS-700-2, GJS-800-2
Austempered Ductile Iron (ADI) EN-GJS-800-8, EN-GJS-1000-5, EN-GJS-1200-2
Carbon Steel C20, C25, C30, C45
Alloy Steel 20Mn, 45Mn, ZG20Cr, 40Cr,   20Mn5, 16CrMo4, 42CrMo,
40CrV, 20CrNiMo, GCr15, 9Mn2V
Stainless Steel Ferritic Stainless Steel, Martensitic Stainless Steel, Austenitic Stainless Steel, Precipitation Hardening Stainless Steel, Duplex Stainless Steel
Aluminium Alloys ASTM A356, ASTM A413,  ASTM A360
Brass / Copper-based Alloys C21000, C23000, C27000, C34500, C37710, C86500,  C87600, C87400, C87800,  C52100, C51100
Standard: ASTM, SAE, AISI, GOST, DIN, EN, ISO, and GB

cast iron shell mould castings

The Advantages of Furan Resin Coated Sand Self-hardening Molding Casting:
1) Improve the dimensional accuracy of castings and the surface roughness.
2) The hardening of the mold (core) sand does not require drying, which can save energy, and inexpensive wood or plastic core boxes and templates can also be used.
3) Self-hardnening molding sand is easy to compact and collapse, easy to clean up castings, and old sand can be recycled and reused, which greatly reduces the labor intensity of core making, modeling, sand falling, cleaning and other links, and it is easy to realize mechanization or automation.
4) The mass fraction of resin in sand is only 0.8%~2.0%, and the comprehensive cost of raw materials is low.

Because the self-hardening method has many of the above-mentioned unique advantages, the self-hardening method is not only used for core making, but also used for casting moulding. It is especially suitable for single piece and small batch production, and can produce cast iron, cast steel and non-ferrous alloy castings. Some Chinese foundries have completely replaced clay dry sand molds, cement sand molds, and partially replaced water glass sand molds.

 

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