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Mid- and Large-Sized Steel Casting Foundry and Machining
Special Alloy Steel Casting for Wear Resistance, and Heat Resistance
LPR’s industrial steel casting foundry specializes in sand casting carbon steel, alloy steel, stainless steel, low temperature steel and heat resistant steel ranging in weight from 2 lbs to 5550 lbs (1 kg-2600 kg). Our expertise extends to producing industrial steel castings that withstand harsh environments including resistance against wear, heat, corrosion, abrasion, and heavy load.
40 years of success in the highly competitive steel casting market is from being R&D focused, and co-developing steel casting methods and materials with clients for their real commercial needs. This allowed our steel casting foundry to be diversified in our steel casting capabilities, being able to serve multiple applications and industries in wider range of steel grades than competitors. Our strength is in producing industrial steel castings and stainless steel castings for harsh environmental conditions against wear, heat, corrosion and abrasion.
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 alloys.
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, alloy steel, stainless steel, corrosion resistant stainless steel with high percent of chromium or manganese like super duplex stainless steel. Our accumulated capability to work with wide range of steel alloys comes from 40 years of pouring to machining industrial stainless steel castings for the valve industry that requires a wide range of materials for various conditions.
| Steel | Standard | Typical Grade |
|---|---|---|
| General Steel Casting | ASTM 216 | WCB, WCA, WCC |
| ASTM 352 | LCB, LCA, LCC, LC1, LC2, LC2-1, LC3, LC4, LC9, CA6NM | |
| JIS G5101 | SC360, SC410, SC450, SC480 | |
| JIS G5102 | SCW410, SCW450, SCW480, SCW550, SCW620 | |
| JIS G5111 | SCC3, SCC5, SCMn1, SCMn2, SCMn3, SCMn5, SCSiMn2, SCMnCr2, SCMnCr3, SCMnCr4, SCMnM3,SCCrM1, SCCrM3, SCMnCrM2, SCMnCrM3, SCNCrM2 | |
| JIS G5151 | SCPH1, SCPH2, SCPH11,SCPH22,SCPH23, SCPH32 | |
| Heat-Resistant Steel Casting | ASTM A297 | HF, HH, HI, HK, HE, HT, HU, HW, HX, HC, HD, HL, HN, HP |
| JIS G5122 | SCH1, SCH2, SCH3, SCH4, SCH5, SCH6, SCH11, SCH12, SCH13, SCH15, SCH16, SCH17, SCH18, SCH19, SCH20, SCH21, SCH22, SCH23, SCH24 | |
| Martensitic Stainless Steel Casting | ASTM A217 | WC1, WC4, WC5, WC6, WC9, WC11, C5, C12, C12A, CA15 |
| JIS G5121 | SCS1, SCS2, SCS3, SCS4, SCS5, SCS6 | |
| Austenitic Stainless Steel Casting | ASTM A351 | CF3, 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 Steel | ASTM A494 | N-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 A560 | 50 Cr-50 Ni | |
| ASTM A743 | CA15, CA15M, CA40, CN3M | |
| ASTM A890 | 1B, 1C, 2A, 3A, 4A, 5A, 6A | |
| JIS G5121 | SCS10, 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 Steel | JIS G5131 | SCMnH1, SCMnH2, SCMnH3, SCMnH4, SCMnH11, SCMnH12, SCMnH21, SCMnH31, SCMnH32, SCMnH33, SCMnH41 |
Introducing Alpha-Set Casting Process
Alpha–set mold casting method is the no-bake sand casting solution applicable for all mold size and metals including steel castings. Alpha–set requires addition of self-hardening caking agent and silica sand, allowing them to cure with a curing agent only. The ability to bind with wide range of ester-based co-reactants make this process suitable and competitive for large scale casting production for steel castings. 90% of the sand can be reclaimed allowing our foundry to reuse most of the sand used in this process. Its pattern release process is smooth, and set times are fast. We use Alpha–set for steel castings with large production quantity, for tight casting metallurgy requirement and casting surface requirement.
Steel Casting Products & Experience
Fluid Control Valves & Pumps
- Ball Valves
- Butterfly Valves
- Turbine Bypass Control Valves
- Single Seated Valves
- Globe Valves
- Knife Gate Valves
- Cage-Guided Valves
- V-Notch Valves
- Turbine Pumps
- Impellers
- Volute Pump
- Cage
- Arm
- Handle Vise
Biomass, Incinerator and Furnace Parts
- Stokers and Grates
- Furnace Trays
- Walking Beam
- Jaw Plate
- Crushers
- Grate Bars and Plates
- Blow Bars
Machinery Parts
- Hammer
- Roller
- Rocking Nut
- Screws
- Covering
Steel Industry
- Liner
- Hammer
- Port Cap
- Grate Plate
- Roller
- Side Wedge
- End Bell / Reducer / Axle
Commercial and Heavy Vehicle Parts
- Swing Bracket
- Cover
- Barrel
- Shar Arm
- Screw
- Roller
- Gearbox
- Arms
- Connecting Rod
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.
Volute Casing & Cover
Pump Casings & Impellers
Valve Disk
Cavity Ball
Hollow Ball
Wafer Butterfly Valve Body
Globe Valve Body
Lug Butterfly Valve Body
Biomass Incinerator Grate Bars
Grate Bar Packing
Inlet Hanger Hinge
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.
Crusher Spare Parts
Sand Crusher Packing
Wear Resistant Mining Castings
Mining Equipment Component Packing
Incinerator Parts
Incinerator T-Plate
Incinerator Cover Plate Liner
Incinerator Grate Bar Head
Kurimoto Crusher Parts
Jaw Crusher Parts
Blow Bars
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.
Roller Hearth Trays & Heat Treatment Furnace Baskets
Cast Mixer Parts
Brackets for Automotive, Train, Elevators
Train, Rail, Locomotive Castings
Cast Iron Pulley Wheel
Tray Roller 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 implemented tight quality control procedure to monitor each process and ensured 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.
| 7/16 | 7/17 | 7/18 | 7/19 | 7/20 | 7/21 | 7/22 | 7/23 | 7/24 | 7/25 | 7/26 | 7/27 | 7/28 | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Mold | 2 pcs | 4 pcs | 5 pcs | 5 pcs | 5 pcs | 3 pcs | |||||||
| Melting Process | 2 pcs | 2 pcs | 4 pcs | 4 pcs | 4 pcs | 4 pcs | 4 pcs | ||||||
| Completion / LP Testing | 2 pcs | 3 pcs | 3 pcs | 3 pcs | 3 pcs | 3 pcs | 3 pcs | 4 pcs | |||||
| Shipment | Arrival 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:
- Material Test Report
- Mill sheet
- LP Test Report
- Commercial Invoice
- Packing List
- Sea Way Bill
Steel Casting Pattern
Steel Casting
Steel Casting
Steel Casting LP Inspection
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 while maintaining our guarantees due to our 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.
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 scan, 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 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 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)