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Steel Casting Manufacturer | Special Steel Alloy Casting for Heat Resistance and Harsh Environment
Our steel and stainless steel castings foundry specializes in producing steel castings in carbon steel, low alloy and high alloy steel, stainless steel, low temperature steel and heat resistant steel from 2 lbs to 5550 lbs. Our expertise extends to producing castings to withstand harsh environments including resistance against wear, heat, corrosion, abrasion, and heavy weight.
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.
Steel Castings Material Capability
Steel castings material capability includes over 200 different types of steel material including carbon steel, stainless steel, and alloy steel with high percent of chromium or manganese. Our accumulated material capability comes from near 40 years of manufacturing 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 |
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
Steel Castings Production Method
CO₂ 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.
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 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 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 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.
| 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 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
Steel Casting
Steel Casting LP Inspection
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.
1. Incoming Raw Materials (Visual Check & Optical, Scale QA)
2. Inspection of Materials (Chemical Composition, Refining, Alloying)
3. Molding (Core Making)
4. Core Setting
5. Casting Mold Assembly
6. Melting & Temperature Monitoring
7. Sample Specimen (Chemical Analysis & Spectrometer QA)
8. Pouring (Temperature, Time, Visual Inspection)
9. Casting Shakeout
10. First Shot Blasting & Surface Cleaning
11. Cutting & Visual Inspection
12. Grinding & Visual Inspection
13. Welding Repair (WPS)
14. NDT – Radiographic (RT), Ultrasonic (UT), Magnetic (MT), Penetrant (DPT)
15. Heat Treatment (Annealing & Normalizing)
16. Second Shot Blasting
17. Optical & Dimensional Inspection of Castings