Continuous Cast Iron Foundry | Grey, Ductile, Spheroidal Graphite Cast Iron Bars

Continuous Iron Casting Foundry for Rotors, Balance Gears, Rolling Mill Rollers, and Hydraulic Blocks

Equipped with 2 continuous grey ductile iron casting lines and automated molten metal transferring systems, our clean and modern foundry facility produces more than 8,000 tons of continuous-casted iron a year. Our main facility includes an induction melting furnace from Otto Junker, a horizontal casting line from Demag Technica, and an automated weighing hopper and crusher system and cored-wire treatment system from Affival. At this automated foundry we produce standard size iron bars and rectangles below.

Standard stock shapes are as below.

We provide custom rough machining and cut sizes at minimum costs from our in-house machining centers, equipped with CNC lathe, duplex milling, peeling and sawing machines right next to the foundry. Final product machining requests are easily accommodated in partnership with US Korea Hotlink machining centers, located within a 1 or 2 hour drive from the foundry.

Continuous Cast Iron Advantages Over Gray Cast Iron or Steel

Continuous ductile cast iron has a uniform dense microstructure with evenly distributed graphite in the form of nodules. This provides ductile iron with greater ductility than gray cast iron containing graphite in flakes. Rounded nodules of graphite in ductile iron inhibit the formation of cracks as opposed to flakes, allowing the material to undergo greater plastic deformation without breaking (i.e., greater ductility).

Please see the microscopic image of our ductile iron below. A dense microstructure ensures no internal defects, and ability to withstand pressure and wear and tear much better than gray cast iron. The dense structure provides excellent dampening of noise and vibration, making continuous cast iron a better choice than steel with similar mechanical properties for many applications- let alone the cost advantage of cast iron over steel.

Ductile Cast Iron Grade Tensile Strength and Hardness 

Ductile Cast Iron Mechanical Properties

Ductile Cast Iron Applications

Our iron castings are mainly supplied to manufacturers of hydraulics and pneumatics, vacuum pumps, compressors, balance shaft for automotive, earth moving machines, machining centers, steel making machinery and steel making. They are in a wide range of industries from semiconductor to automotive to steel to machinery industry.

The most common applications for hydraulic systems are hydraulic system blocks for valves, cylinders and distribution due to its rigidity and density.

Screw rotors for compressors are another popular application for cast iron. We have been supplying vacuum pump rotors to global vacuum pump manufacturers, including Rexroth, for over 20 years. Our cast iron’s uniform density makes an ideal material for rotors, which move at high speed with exposure to vibration because it dampens noise and vibration. Uniform density also results in a glassy smooth surface, which helps the rotor lubricity and eccentricity for its rotational balance.

Balance gear and pulley manufacturers are another client group who prefer continuous cast iron over forged steel for cast iron’s dampening effect of noise and vibration.   

Cast Iron Project Experience

Project: Conveyor Roller for Stelmor Controlled Conveyor Cooling System

Client: Primetals
Material: HD5R
Product: Conveyor Roller
Application: For Stelmor Controlled Conveyor Cooling System
Total product weight: 251 tons

Project: TATA Steel Wire Rod Mill (WRM) Upgrade

Material: HD5R
Product: Conveyor Roller
Application: For Stelmor Controlled Conveyor Cooling System
Total product weight: 66 tons

Project: Material for Canadian Nuclear Power Plant

Material: HD4
Product: Continuously Cast Ferritic Ductile Iron; Pressure-Retaining Casting for Use at Elevated Temperatures
Total product weight: 200 tons

Project: Blank Cast Bars for Electrical Equipment Part Molds

Material: H3, H3M
Product: As-Cast Bar, Permanent Mold
Total product weight: 142 tons