Iron Casting Foundry for Machine Tool, Hammer Union and Mud Pump Components
Furan Resin and Green Sand Iron Castings with Machining Capability
Our iron castings come from S.Korea at a iron casting foundry with in-house machining center that has more than 40 years supplying iron castings for globally known machine tool manufacturers, valve makers, mud pump manufacturers and hammer union companies.
Iron castings are supplied from a ISO 9001, ISO/TS 16949, ISO 14001, and OHSAS 18001 certified facility and we also hold marine class certifications from multiple major marine associations including ABS, Lloyd’s DNV, BV,and GL for the cast iron marine and ship components.
The foundry produces raw iron castings to fully machined parts with high quality casting pattern. From the casting design, 3D simulation, casting inspection and quality check are performed in one of the two factories to ensure that we keep the lead time and casting quality in control. We use a self-developed quality control system called Process Info Management System which allows project managers and engineers to observe and record every manufacturing process for maximized traceability.
Our global iron casting clientele includes Gardner Denver Inc, GE Power and Water, Caterpillar Inc, Honeywell, Metaldyne Performance Group Inc, Doosan Infracore, and more. Full list is below.
Iron Casting Foundry for Mud Pump Components, Marine Engine Components, Valves and Hammer Union, Machine Tool Components
Daehan Special Metal Co., Ltd is LPR Global’s cast iron component manufacturer with more than 40 years of history as an iron casting component manufacturer. To meet the growing demand from multiple global clients, they have expanded their iron casting foundry to 17,490 m2. Our iron castings are mainly supplied to manufacturers of mud pumps, hammer unions, injection molding machine, press machines, machine tools, valves and ships.
Materials that are casted include commonly used materials like grey cast iron, and ductile cast iron but also special iron alloy including meehanite cast iron, nickel resistant cast iron for applications requiring strong resistance to heat, wear and corrosion.
Our cast iron components weight from 0.5kg to its heaviest at 9 tons, and approximately 2500 tons of iron castings are produced every month on average.
Iron Casting Process
- Furan Resin Casting – 900 ton / month
- Disamatic Casting Capacity – 600 ton / month
- AMF Casting Capacity – 1000 ton / month
- Total iron casting of approximately 2500 ton / month
Iron Casting Production Capability
|Maximum Dimension Casted|
|Iron Casting Weight|
Iron Casting Materials
We often need to use special iron casting materials outside of grey cast iron and ductile cast iron. These are used for larger sized industrial parts under critical environments. Our iron casting foundry has extensive experience casting austenitic ductile iron for applications that require dimensional stability and strength even under high temperatures, and resistance against corrosion and oxidation. Meehanite cast iron is used as a material for applications requiring uniformity in mechanical and physical properties, and Hi-Sil Moly ductile iron castings are used for industrial applications that require anti-corrosive, anti-erosive, and anti-friction wear up to 1400F (760C). Our iron casting foundry’s thermal analysis program uses ATAS dynamic inoculation to identify the optimum melting condition for ductile cast iron and gray cast iron.
Grey Cast Iron
Special Alloy Cast Iron
Ductile Cast Iron
Commonly Produced Cast Iron Components
- Mud Pumps and Turbo Pumps – Cover, Gearbox, Cooler, Connecting Rod, Pump Body
- Industrial Grade Compressors – Impeller Casing,
- Turbine Housings
- Bearing Housings
- Machine Tool and Machinery Components – Machine Tool Bed, CNC Bed
- Injection Molding Machine – Machine Bed, Frange Components, Frames
- Marine and Offshore Components – Oil Pan, Azimuth Thruster, Engine Gear House, Flange, Engine Front Box
Iron Casting Foundry’s Production Process
At our iron casting foundry and machining shop, we use multiple programs for simulation before production, manufacturing process check and for quality check to control and monitor all casting process to its finishing touches. To manage these process, we collect casting data, then analyze the measured data, and testing results for each step. This also allows project managing engineers to be able to control each equipment and monitor the data analysis of the defect history, and composition specification. Our iron casting foundry uses A Nova flow and solid program as well as an AnyCasting system for simulating the casting method before casting process. The simulation step includes analysis of pouring methods, solidification steps. Our cast iron production process is outlined below:
- Designing patterns and PC simulation to verify casting method before iron casting
- Making casting mold
- Sand molding automated process
- Closing molds by cope and drag method
- Melting pig iron and pressed scrap to get liquid metal using induction furnace
- 1st element analysis
- Tapping to pour liquid metal into the pot
- 2nd element analysis
- Pouring molten iron alloy casting into a sand mold
- Separating iron casting from a sand mold
- Degating inlets and feeders
- Shot blasting and grinding for deburring
- Final inspection of the casting
List of Equipment Used For Iron Casting and Machining
Cast Iron Projects
Grey cast iron cooler for turbo compressors
400MPa and weight range: 1.5 ton to 3 ton
Grey cast iron injection molding machine bed
Casting method: sand casting with furan resin sand mold
300MPa and weight range: 3 ton to 9 ton
Ductile cast iron injection molding machine frame
400MPa, 3 ton post machining
Ductile cast iron injection molding machine frange component
450MPa, 5 ton post machining
Grey cast iron CNC bed
300MPa and weight range: 3 ton to 9 ton
Grey cast iron protective plate covering for steel mill
250MPa, weight range: 2 ton to 2.3 ton.
Also casted in ductile cast iron 450MPa
Iron casted and machined machine tool bed
Ductile cast iron connecting rod for mud pump
(550Mpa weighing 0.405ton)
Iron casted gear box and cover casting for turbo compressor
Weight range: 100kg to 1 ton.
Grey cast iron pump body
200MPa and weight range: 200kg to 2 ton.
Grey cast iron impeller casing
200MPa and weight range: 21kg to 54.5kg
Grey cast iron casing
200MPa and weight range: 7kg to 15kg
Grey cast iron pump body
200MPa and weight range: 10kg to 25kg
Iron Casted Wind Mill, Marine and Shipbuilding Components
Grey cast iron marine oil pan
400MPa and weight range: 2ton to 3 ton
Iron casted azimuth thrust inner stem ranging in diameter from 1100mm to 2500mm
Grey cast iron marine engine gear house
400MPa and weight range: 1ton to 8ton
Iron casted and machined flange for offshore crane (Diameter 3000mm, Height 450mm, Width 150mm)
Grey cast iron gear case for wind mill
400MPa and weight range: 1ton to 3ton
Grey cast iron marine engine front end box
250MPa and weight range: 1 ton to 4ton
Cast Iron Components Clienteles
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