Iron Castings for Machine Tools, Hammer Unions and Mud Pumps

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 Production Capability

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.

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 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:

1. Designing patterns and PC simulation to verify casting method before iron casting
2. Making casting mold
3. Sand molding automated process
4. Closing molds by cope and drag method
5. Melting pig iron and pressed scrap to get liquid metal using induction furnace
6. 1^st element analysis
7. Tapping to pour liquid metal into the pot
8. 2^nd element analysis
9. Pouring molten iron alloy casting into a sand mold
10. Separating iron casting from a sand mold
11. Degating inlets and feeders
12. Shot blasting and grinding for deburring
13. Final inspection of the casting

Equipment List For Iron Casting and Machining

Cast Iron Project Experience

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