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.

Business Areas

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

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

Globe Valve Bodies and Components | Casting Foundry

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 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.

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 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.

 

 7/167/177/187/197/207/217/227/237/247/257/267/277/28
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 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:

 

  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

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.

SteelStandardTypical Grade
General Cast SteelASTM 216WCB, WCA, WCC
ASTM 352LCB, LCA, LCC
JIS G5101SC42, SC46, SC49
JIS G5151SCPH1, SCPH2
Low-Alloy SteelASTM A217
JIS G5111
WC1, WC4, WC5, WC6, WC9, C12A
SCMnCr2, SCMnCr3
SCMnCr4, SCMn1, SCMn2, SCMn3, SCMn5
HC, HD, HH, HE, HK30, HP
SCH2, SCH11, SCH13, SCH17, SCH21, SCH24
Corrosion-Resistant Stainless SteelASTM A351CF8(M), CF3(M), CN7M, CK3MCuN, CF3MN
JIS G5121SCS13(A), SCS14(A), SCS16(A), SCS19(A), SCS23
Wear-Resistant Stainless SteelASTM A743
JIS G5121
CA15, CA40, CA15M
CA6NM
SCS1, SCS2, SCS3
Ni-base SteelASTM A494N-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 A890CD4MCuN(1B), CD3MN(4A)
CD3MCuN(1C), CE3MN(5A)
CE8MN(2A), CD3MWCuN(6A)
CD6NM(3A)

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.

Grinding | Jobber Casting Foundry

1. Incoming Raw Materials (Visual Check & Optical, Scale QA)

Inspection of Materials (Chemical Composition, Refining and Alloying)

2. Inspection of Materials (Chemical Composition, Refining, Alloying)

Core Making Process | Casting Foundry

3. Molding (Core Making)

Mold Making Process | Core Setting | Casting Foundry

4. Core Setting

Casting Mold Assembly Process | Jobber Foundry

5. Casting Mold Assembly

Melting | Heat Resistant Steels, Cast Steels, Low-Alloy Steels, Duplex Steels

6. Melting & Temperature Monitoring

Specimen Sample Prior to Pouring | Casting Foundry

7. Sample Specimen (Chemical Analysis & Spectrometer QA)

Pouring | Duplex, Abrasion Resistant, Corrosion Resistant, Heat Resistant Stainless Steels

8. Pouring (Temperature, Time, Visual Inspection)

CO2 Casting & Sand Casting Shakeout | Jobber Foundry

9. Casting Shakeout

Shot Blasting | Heat & Wear Resistant Castings

10. First Shot Blasting & Surface Cleaning

Cutting | Jobber Castings Foundry

11. Cutting & Visual Inspection

Grinding | Jobber Casting Foundry

12. Grinding & Visual Inspection

Welding Repair (WPS) | Jobber Casting Foundry

13. Welding Repair (WPS)

NDT Testing - Radiographic Testing (RT), Ultrasonic Testing (UT), Magnetic Testing (MT), Dye Penetrant Testing (DPT)

14. NDT – Radiographic (RT), Ultrasonic (UT), Magnetic (MT), Penetrant (DPT)

Heat Treatment of Castings | Duplex Stainless Steel Foundry

15. Heat Treatment (Annealing & Normalizing)

Second Shot Blasting Process | Jobber Casting Foundry

16. Second Shot Blasting

Final Optical and Dimensional Inspection | Industrial Castings Foundry

17. Optical & Dimensional Inspection of Castings

Packed Grate Bars for Biomass Incinerators | Precision Casting Foundry

18. Packing & Delivery

Shell Molding & Sand Casting Video

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