Shell Molding & Sand Castings Foundry | Heat, Wear, Abrasion, and Corrosion Resistant Steels
Steel Castings for Mining, Rail, Municipal, Power Generation, Machinery, Industrial Plants, and Steel Mills
Founded in 1989, our shell molding and sand castings foundry based in Cheonan, Korea is a TUV ISO 9001:2008 certified facility for castings of carbon steels and stainless steels and is also Lloyd’s and DNV marine classification certified. Through our diverse experience with various industries, we are able to meet a wide range of casting requirements for the mining, locomotive, power generation, and petrochemical industry. We have a production capacity of 300 tons and the capability of producing green sand castings up to 2,500 kg.
Some of our exemplary clients include companies such as Doosan Heavy Industries, Hyundai Steel, POSCO, Dongwoo Finechem, Advance Valve Solutions, Metso, WEIR, and Kurimoto.
Industrial Castings | Carbon Steel, Stainless Steel, Alloy Steel
Our foundry in South Korea was founded in 1989, specializing in producing various wear-, heat-, corrosion-, and abrasion-resistant castings. Typical castings include a range of carbon and carbon-manganese steels (SCHP2, WCB), austentic stainless steels (SCS14A, CF8M), and various alloy steels (SCHP32/CF, WC9).
Our 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 materials.
We utilize high speed induction furnaces and have 3 ton ladles to producing steel casting weights ranging from 1 kg to 2,500 kg. The majority of our processes are conducted in-house including nondestructive x-ray and gamma-ray (Co-60 & Ir-192) radiography testing.
- On-Off Ball Valves
- Turbine Bypass Control Valves
- Single Seated Valves
- Heat Treatment Furnace Grates
- Butterfly Valves
Mining Wear Parts
- Machine Parts
- Jaw Plate
- Grate Bars
- Blow Bars
- V-Notch Valves
- Biomass Incinerator Components
- Globe Valves
- Cage-Guided Valves
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
Wafer Butterfly Valve Body
Globe Valve Body
Lug Butterfly Valve Body
Biomass Incinerator Grate Bars
Grate Bar Packing
Inlet Hanger Hinge
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 steels 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 Cover Plate Liner
Incinerator Grate Bar Head
Kurimoto Crusher Parts
Jaw Crusher Parts
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 Mill Casting 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 castings by. Our US client was looking for a casting shop 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 ensured the process to make zero defects. We first shared our manufacturing schedule that outlined 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.
|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 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 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.
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 LP Inspection
Standard Cast Material Grades
Aside from the list of materials that we cast on a regular basis, we are also able to accommodate many requests for other types of materials.
|General Cast Steel||ASTM 216||WCB, WCA, WCC|
|ASTM 352||LCB, LCA, LCC|
|JIS G5101||SC42, SC46, SC49|
|JIS G5151||SCPH1, SCPH2|
|Low-Alloy Steel||ASTM A217|
|WC1, WC4, WC5, WC6, WC9, C12A|
|SCMnCr4, SCMn1, SCMn2, SCMn3, SCMn5|
|HC, HD, HH, HE, HK30, HP|
|SCH2, SCH11, SCH13, SCH17, SCH21, SCH24|
|Corrosion-Resistant Stainless Steel||ASTM A351||CF8(M), CF3(M), CN7M, CK3MCuN, CF3MN|
|JIS G5121||SCS13(A), SCS14(A), SCS16(A), SCS19(A), SCS23|
|Wear-Resistant Stainless Steel||ASTM A743|
|CA15, CA40, CA15M|
|SCS1, SCS2, SCS3|
|Ni-base Steel||ASTM A494||N-12MV(HASTELLOY B), CW-12MW(HASTELLOY C), CZ-100, CY40(INCONNEL), M35-1, M30C(MONEL), ALLOY 20 (UNS N08020)|
|Duplex Stainless Steels (Austenitic/Ferritic)||ASTM A890||CD4MCuN(1B), CD3MN(4A)|
Manufacturing & Casting Process
Our foundry utilizes CO2, Sand Casting, and Shell Mold Casting processes. Depending on the size and shape of the casting, we are capable of producing sand castings up to 2,500 kg and shell mold castings up to 50 kg. Typical castings that we produce include components for valves, pumps, machinery, mining, train, and refuse biomass incinerator components.
Nondestructive testing (RT, UT, MT, PT) is performed in-house and with third-party NDT inspection companies with DNV-certified inspectors. Our in-house radiographic testing (RT) equipment includes x-ray, iridium (Ir-192), and cobalt (Co-60) gamma ray testing.