Industrial Steel Castings & Stainless Steel Casted Components

Heat, Wear, and Corrosion Resistant Steel Castings for Valves, Pumps, Tools, and Construction Machines

LPR Global is a global supplier of industrial steel castings and stainless steel casting based machined parts with a foundry based in Cheonan, Korea. Industrial steel casting and stainless steel casting capabilities are specialized for tools, pumping & fluid control, tube supports and other industrial components for oil & gas applications, power generation and construction industries.

40 years of success in the highly competitive steel casting market and industries is due to our heavily R&D focused, and co-developing steel casting methods and materials for customer’s real commercial needs. Our strength is in producing industrial steel castings and stainless steel castings for harsh environmental conditions against wear, heat, corrosion and abrasion

Industrial Steel Casting Foundry | Special Alloy Steel Casting for Heat Resistance and Harsh Environment

LPR’s industrial steel casting foundry specializes in producing steel castings in carbon steel, alloy steel, stainless steel, low temperature steel and heat resistant steel from weight range of 2 lbs and 5550 lbs.  Our expertise extends to producing industrial steel castings to withstand harsh environments including resistance against wear, heat, corrosion, abrasion, and heavy weight.

 

The refining and alloying practice includes Carbon, Metal Nickel, Ferro Chrome, Ferro Molybdenum, Ferro Silicon, Ferro Manganese, Copper, Nitrogen-Chrome, Columbium, Titanium, Tungsten, Aluminum, Vanadium, and Calcium-Silicon. We may also be able to accommodate special requests for other steel based casting materials.

Industrial Steel Casting Material Capability

Our industrial steel casting material capability includes over 200 different types of steel materials and grades in wide range of international standards  including carbon steel, stainless steel, and alloy steel with high percent of chromium or manganese. Our accumulated capability to work with wide range of steel alloys comes from 40 years of pouring to machining industrial steel castings for the valve industry that requires a wide range of materials for various conditions.

SteelStandardTypical Grade
General Steel CastingASTM 216WCB, WCA, WCC
ASTM 352LCB, LCA, LCC, LC1, LC2, LC2-1, LC3, LC4, LC9, CA6NM
JIS G5101SC360, SC410, SC450, SC480
JIS G5102SCW410, SCW450, SCW480, SCW550, SCW620
JIS G5111SCC3, SCC5, SCMn1, SCMn2, SCMn3, SCMn5, SCSiMn2, SCMnCr2, SCMnCr3, SCMnCr4, SCMnM3,SCCrM1, SCCrM3, SCMnCrM2, SCMnCrM3, SCNCrM2
JIS G5151SCPH1, SCPH2, SCPH11,SCPH22,SCPH23, SCPH32
Heat-Resistant Steel CastingASTM A297
HF, HH, HI, HK, HE, HT, HU, HW, HX, HC, HD, HL, HN, HP
JIS G5122SCH1, SCH2, SCH3, SCH4, SCH5, SCH6, SCH11, SCH12, SCH13, SCH15, SCH16, SCH17, SCH18, SCH19, SCH20, SCH21, SCH22, SCH23, SCH24
Martensitic Stainless Steel CastingASTM A217WC1, WC4, WC5, WC6, WC9, WC11, C5, C12, C12A, CA15
JIS G5121SCS1, SCS2, SCS3, SCS4, SCS5, SCS6
Austenitic Stainless Steel CastingASTM A351CF3, CF3A, CF8, CF8A, CF3M, CF3MA, CF8M, CF3MN, CF8C, CF10, CF10M, CH8, CH10, CH20, CK20, HG10, HK30, HK40, HT30, CF10MC, CN7M, CN3MN, CG6MMN, CG8M, CF10SMnN, CT15C, CK3MCuN, CE20N, CG3M
Corrosion-Resistant Stainless SteelASTM A494N-12MV (Hastelloy B), CW-12MW (Hastelloy C), CW6MN (Inconel 625), CW12MW (Hastellow C276), CZ-100, CY40 (Inconnel), M35-1 (Monel 400), M30C, M30H, M25S (Monel S), ALLOY 20 (UNS N08020)
ASTM A56050 Cr-50 Ni
ASTM A743CA15, CA15M, CA40, CN3M
ASTM A8901B, 1C, 2A, 3A, 4A, 5A, 6A
JIS G5121SCS10, SCS11, SCS12, SCS13, SCS14, SCS14A, SCS15, SCS16, SCS17, SCS18, SCS19, SCS19A, SCS20, SCS21, SCS22, SCS23, SCS24, SCS31, SCS32, SCS33, SCS34, SCS35, SCS36
Wear-Resistant Stainless SteelJIS G5131SCMnH1, SCMnH2, SCMnH3, SCMnH4, SCMnH11, SCMnH12, SCMnH21, SCMnH31, SCMnH32, SCMnH33, SCMnH41

Industrial Steel Casting Applications

Industrial Plants

  • On-Off Ball Valves
  • Turbine Bypass Control Valves
  • Single Seated Valves
  • Heat Treatment Furnace Grates
  • Butterfly Valves

Mining Wear Parts

  • Incinerators
  • Machine Parts
  • Hammers
  • Jaw Plate
  • Liners
  • Crushers
  • Grate Bars
  • Blow Bars

Power Generation

  • V-Notch Valves
  • Biomass Incinerator Components
  • Globe Valves
  • Cage-Guided Valves
  • Impellers
Shot Blasting and Casting Facility

Industrial Steel Casting Production Method

CO₂ Process

CO2 Process

Shell Mould Process

Shell Mould Process

Power Generation & Industrial Plant Steel Castings

We have over 25 years of experience casting carbon steel and stainless steel valves and valve components for the power generation and industrial plants include globe valves, check valves, ball valves, butterfly valves (BFV), plug, rotary, safety, strainer, and gate valves. We also produce complex shaped steel castings for volute covers, pump casings, and impellers.

 

Our expertise in shell mold casting of various heat resistant and wear resistant steels allows us to maintain tight casting tolerances. Due to the ability to maintain close tolerances for products such as biomass incinerator grate bars, many of our clients have often found that minimal or no further post-casting machining process is required thus resulting in time and cost savings.

Foundry | Cast Pump Casings, Volute Covers, Impellers

Volute Casing & Cover

Foundry | Cast Pump Casings, Volute Covers, Impellers

Pump Casings & Impellers

Valve Components | Valve Disc | Casting Foundry

Valve Disk

Cavity Ball Valve Component Castings | Precision Casting Foundry

Cavity Ball

Hollow Ball Valve Component Castings | Jobber Foundry

Hollow Ball

Wafer Butterfly Valve Body | Castings for Power Generation

Wafer Butterfly Valve Body

Steel casted globe valve bodies

Globe Valve Body

Plant Industry & Power Generation Industry | Lug Butterfly Valve Body

Lug Butterfly Valve Body

Wear Resistant and Heat Resistant Biomass Incinerator Grate Bar Castings

Biomass Incinerator Grate Bars

Packed Grate Bars for Biomass Incinerators | Precision Casting Foundry

Grate Bar Packing

Wear-Resistant Cast Inlet Hangers

Inlet Hanger Hinge

Cast Elbows | Power Generation & Plant Industries

Cast Elbow

Mining Industry | Wear & Abrasion Resistant Steel Castings

Our team is experienced in producing steel castings for the mining industry using wear resistant and corrosion resistant steel alloys for impact resistance, high abrasion resistance, and high corrosion resistant properties.

Steel spare parts castings for mining equipment include sand crushers, jaw crusher, cone crusher, roller crusher, VSI crusher, grinding mill liners, chutes, brow bar, jaw plate, hammer, liner blocks, round hammer, corner guides, and incinerators.

Mining Industry | Impact and Abrasion Resistant Castings | Sand Crusher Components

Crusher Spare Parts

Mining Industry Castings | Sand Crushers

Sand Crusher Packing

Mining Industry | Impact and Abrasion Resistant Castings | Sand Crusher Parts

Wear Resistant Mining Castings

Precision Casting Foundry | Sand Crusher Parts | Mining Industry

Mining Equipment Component Packing

Jobber Foundry Castings | Heat Resistant & Wear Resistant Components

Incinerator Parts

Heat and Wear Resistant Incinerator T-Plate

Incinerator T-Plate

Incinerator Cover Plate | Heat Resistant Castings | Jobber Foundry

Incinerator Cover Plate Liner

Biomass Incinerator Grade Bar Head | Wear Resistant Castings

Incinerator Grate Bar Head

Kurimoto Sand Crusher Packing

Kurimoto Crusher Parts

Wear Resistant Blow Bar Castings

Jaw Crusher Parts

Cr & Mn Castings | Blow Bars | Mining Industry

Blow Bars

Blow Bar Drawings | Foundry Castings

Cr & Mn Castings

Industrial Steel Castings | Rail, Automotive, Equipment & Machinery

We have a wide range of experience producing wear resistant steel castings for industries such as rail stock, locomotive, automotive brackets, and elevator components. Our heat resistant steel castings for high temperature applications include heat treatment furnace parts, batch roller trays, roller hearth trays, and cast baskets.

Heat Treatment Furnace Grates | Heat and Wear Resistant Castings

Roller Hearth Trays & Heat Treatment Furnace Baskets

Precision Cast Mixer Parts

Cast Mixer Parts

Bracket for Rolling Stock, Elevators, Automotive

Brackets for Automotive, Train, Elevators

Wear Resistant Castings for Train, Rail, and Locomotive

Train, Rail, Locomotive Castings

Trim | Train and Industrial Castings

Cast Iron Pulley Wheel

Tray Roller Castings | Train and Locomotive

Tray Roller Castings

Tray Roller | Rail Car & Industrial Castings

Other Industrial Castings

Steel Castings for Steel Mill Project Case: High quantity, strict quality steel castings under tight deadline

The biggest challenge for this steel casting project was the tight deadline that our client needed the steel castings by. Our US client was looking for a steel casting foundry that was able to accommodate their aggressive deadline that most other shops were not able to accommodate. We had to tightly manage the project; we calculated the exact time that each process takes from wooden pattern design to manufacturing and casting production; then we followed out tight quality control procedure to monitor each process and ensure that  there are zero defects along the way. We first shared our manufacturing schedule outlining the number of end bells we were scheduled to finish each day from molding process, melting process, casting completion, LP inspection to shipment. We also reported our manufacturing process on a regular basis.

 

 7/167/177/187/197/207/217/227/237/247/257/267/277/28
Mold2 pcs4 pcs5 pcs5 pcs5 pcs3 pcs
Melting Process2 pcs2 pcs4 pcs4 pcs4 pcs4 pcs4 pcs
Completion / LP Testing2 pcs3 pcs3 pcs3 pcs3 pcs3 pcs3 pcs4 pcs
ShipmentArrival at Port

 

This client specifically required our steel casting foundry to carry out LP inspection to 100% of the castings under the requirement condition SPR-LPR/APR to NF EN 1371-1. Weld areas were to be cleaned up to SP3/CP3 standards, and LP3/AP3 to EN1371-1 (100% testing) when machined. Mechanical testing, chemical composition, and LP inspection were performed on 100% of the steel castings, and reports were sent for client’s review upon shipping. Material certificate was also to be reported for all steel castings with the heat treatment number written in visible location for each casting. Each casting was individually wrapped in a special anti-corrosive coated packaging and placed into a wooden box to be shipped overseas.

List of documents provided with the shipment, including quality inspection report:

  1. Material Test Report
  2. Mill sheet
  3. LP Test Report
  4. Commercial Invoice
  5. Packing List
  6. Sea Way Bill
End Bell Steel Casting Pattern

Steel Casting Pattern

End Bell Steel Casting 2

Steel Casting

End Bell Steel Casting

Steel Casting

Steel Casting LP testing report

Steel Casting LP Inspection

Steel Casting Individually Packaged

Castings were individually packaged in vacuum packaging and placed into wood boxes after being coated with anti-corrosive oil. Because these castings had to be ready for further machining, we used anti-corrosive oil with thinner viscosity, that allows easier clean up.

Industrial Casting Quality Control

Consistent and outstanding quality under promised manufacturing schedule is how we differentiate ourselves as an industrial steel casting supplier against competitors. We are able to promise our new and returning clients a competitive lead time and price and keep our promise because we have strict quality control procedure in place for every casting production process from scrap melting to steel casting inspection. Steel casting quality for industrial applications such as fluid control, pressure controls for power plants, and chemical plants are especially critical and we have been maintaining the reputation as a quality steel castings provider for years.

Ceramic Mould Casting Method

Our industrial steel casting foundry have added ceramic mould casting method to expand our casting ability to steel cast more complicated shapes, tighten the steel casting’s dimensional tolerances, and allow our clients to reuse the casting pattern for returning orders or large orders.

Ceramic Moulding Steel Casting

Steel Casting Pattern & Mold Molding Process

Reverse engineering & drawing designing process is used for steel castings without drawings. We examine the physical part, process a 3D scanning, and then use a finite element analysis program (FEA) to design a predictive computational models of both casting and the pattern. We then pull up a 3D CAD model and review an analysis report to examine the casting and it’s pattern design.

Our steel casting plan and wood pattern design is done in cooperation between casting engineers and the advisory R&D engineers to come up with a design free of cracks, shrinks, and internal pores.

Wooden patterns are CNC machined up to thickness of 100um. The casting patterns and steel castings are examined for its shrinkage rate by section.

Steel Casting Pattern Making
Industrial Steel Casting Pattern Design Process

Steel Casting Melting Process

The melting process of industrial steel casting production starts with alloy designing process, where material engineer analyzes the amount of ferrous materials and scraps to come up with the required chemical composition of the casting. We use certified ferrous materials and scraps to melt in our melting furnace. The scrap melting process is followed by a degassing process using Ca-Si or Fe-Ti based deoxiders.

Steel Casting Chemical Composition Check

To obtain a high quality steel casting, before steel casting is poured out in mass-scale, a small sample casting is poured out, polished and sent in for a spectroanalysis. The chemical composition result is compared against the target chemical composition of required steel grade. Once this sample casting’s spectroanalysis is approved, we proceed to the pouring process. Finished castings are sent in for a Y block tensile check.

Steel Casting Sample
Steel Casting Polishing
Steel Casting Spectro analysis

Steel Casting NDE Quality Testing

 

Our industrial steel casting foundry provides and suggest wide range of quality inspection methods to clients depending on their priority. For instance, for customers that are more cost sensitive, but seeking castings that are not used in critical applications, our engineers evaluate the need for vigorous quality examination. For steel castings that are required in critical environment, we might recommend a more vigorous quality examination than what the customer has requested if it is required to confirm that the final castings meet the required quality.

Some of our none destructive quality inspection methods include:

  • PT Test (Penetrant Testing)
  • LP Test (Liquid Penetrant Testing)
  • RT (Radiographic Testing)

Our regular quality examination methods include:

  • Mechanical Properties Testing: Tensile Test, Hardness Test, Charpy Impact Testing
  • Corrosion Test: Salt Spray Corrosion Test using 5% NaCl Solution and examining degree of corrosion every 168 hours (1 week)

Shell Molding & Sand Casting Video

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