Office Line
+86-15763932413
+86-15763932413
English  |
Chifine
OEM Ductile Iron Shell Mold Casting Parts provide high-precision solutions for industries requiring complex, load-bearing components with superior surface quality, including automotive transmissions, industrial valves (oil, gas, and water), heavy machinery housings, and aerospace structural brackets. Shell mold casting—a process utilizing phenolic resin-bonded sand molds cured at 200-300°C—enables the production of intricate geometries (e.g., internal cavities, thin walls, and threaded features) that traditional sand casting cannot achieve, reducing assembly steps by 30% . Our OEM parts adhere to ASTM A536 standards, ensuring consistent mechanical properties across production batches (with tensile strength variation <5%) for clients in aerospace, energy, and construction sectors, including Fortune 500 equipment manufacturers .
We use ductile iron (ASTM A536 Grade 80-55-06), a spheroidal graphite cast iron alloy renowned for its combination of strength, ductility, and machinability. This grade achieves a tensile strength of 552 MPa, yield strength of 380 MPa, and elongation of 6%, outperforming gray iron in impact resistance (20 J minimum at -20°C) and fatigue strength (220 MPa at 10^7 cycles) . The material composition includes 3.2-3.6% carbon (for castability), 2.4-2.8% silicon (graphitization promoter), and 0.03-0.05% magnesium (to convert flake graphite to spheroidal particles)—eliminating the brittleness associated with flake graphite in gray iron. This spheroidal structure also improves thermal conductivity (45 W/m·K), making it suitable for heat-exchange components .
Shell mold casting produces parts with Ra 12.5μm surface roughness without secondary machining, reducing friction in moving components like gear housings by 15% compared to sand-cast parts. The phenolic resin binder creates a hard, smooth mold surface (Rockwell hardness 45 HRC) that transfers to the casting, minimizing porosity (less than 2% volume) and sand inclusion defects (0.1 defects per 100cm²) . Surface profilometry inspections are conducted on 100% of critical surfaces to ensure consistency.
The rigid shell mold (3-6mm thickness) resists expansion during pouring (thermal expansion coefficient <0.01%/°C), achieving dimensional tolerances of ±0.2mm/m—30% tighter than conventional sand casting. This precision reduces assembly time by 25% and ensures proper fit in multi-component systems, such as valve assemblies with tight clearance requirements (0.05-0.1mm) . Coordinate Measuring Machine (CMM) inspections with 0.001mm accuracy verify key dimensions on every production lot.
Parts can be customized with heat treatments to enhance specific properties:
• Ferritizing anneal (800-850°C for 2 hours) for improved machinability in valve bodies, reducing tool wear by 40%
• Quench and temper (850°C quench, 550°C temper) for high-wear applications (hardness up to 300 HB), suitable for gear teeth and bearing surfaces
• Isothermal annealing to reduce internal stress in large-diameter (≥200mm) components, minimizing distortion during subsequent machining by 0.05mm/m
Our OEM capabilities support clients from design to production:
• Engineering support: DFM analysis to optimize gating, risering, and mold design for complex features (e.g., undercuts, thin walls <5mm) using simulation software (MAGMAsoft) to predict and prevent defects
• Material customization: Grades from 60-40-18 (high ductility for shock-loading applications) to 120-90-02 (high-strength for heavy machinery) based on application requirements, with material certificates (PMI testing) provided
• Testing protocols: Ultrasonic inspection (for internal defects), magnetic particle testing (for surface cracks), and tensile testing with full traceability reports (batch-to-customer tracking)
• Production scalability: Volumes from 500 to 100,000+ units/year with lead times of 4-6 weeks for tooling (shell mold patterns) and 2-3 weeks for production, supported by 3 shifts operation
• Value-added services: Machining (CNC turning/milling), coating (epoxy, zinc plating), and assembly (bearing press-fit, seal installation) to deliver ready-to-install components, reducing client assembly time by 30%
OEM Ductile Iron Shell Mold Casting Parts provide high-precision solutions for industries requiring complex, load-bearing components with superior surface quality, including automotive transmissions, industrial valves (oil, gas, and water), heavy machinery housings, and aerospace structural brackets. Shell mold casting—a process utilizing phenolic resin-bonded sand molds cured at 200-300°C—enables the production of intricate geometries (e.g., internal cavities, thin walls, and threaded features) that traditional sand casting cannot achieve, reducing assembly steps by 30% . Our OEM parts adhere to ASTM A536 standards, ensuring consistent mechanical properties across production batches (with tensile strength variation <5%) for clients in aerospace, energy, and construction sectors, including Fortune 500 equipment manufacturers .
We use ductile iron (ASTM A536 Grade 80-55-06), a spheroidal graphite cast iron alloy renowned for its combination of strength, ductility, and machinability. This grade achieves a tensile strength of 552 MPa, yield strength of 380 MPa, and elongation of 6%, outperforming gray iron in impact resistance (20 J minimum at -20°C) and fatigue strength (220 MPa at 10^7 cycles) . The material composition includes 3.2-3.6% carbon (for castability), 2.4-2.8% silicon (graphitization promoter), and 0.03-0.05% magnesium (to convert flake graphite to spheroidal particles)—eliminating the brittleness associated with flake graphite in gray iron. This spheroidal structure also improves thermal conductivity (45 W/m·K), making it suitable for heat-exchange components .
Shell mold casting produces parts with Ra 12.5μm surface roughness without secondary machining, reducing friction in moving components like gear housings by 15% compared to sand-cast parts. The phenolic resin binder creates a hard, smooth mold surface (Rockwell hardness 45 HRC) that transfers to the casting, minimizing porosity (less than 2% volume) and sand inclusion defects (0.1 defects per 100cm²) . Surface profilometry inspections are conducted on 100% of critical surfaces to ensure consistency.
The rigid shell mold (3-6mm thickness) resists expansion during pouring (thermal expansion coefficient <0.01%/°C), achieving dimensional tolerances of ±0.2mm/m—30% tighter than conventional sand casting. This precision reduces assembly time by 25% and ensures proper fit in multi-component systems, such as valve assemblies with tight clearance requirements (0.05-0.1mm) . Coordinate Measuring Machine (CMM) inspections with 0.001mm accuracy verify key dimensions on every production lot.
Parts can be customized with heat treatments to enhance specific properties:
• Ferritizing anneal (800-850°C for 2 hours) for improved machinability in valve bodies, reducing tool wear by 40%
• Quench and temper (850°C quench, 550°C temper) for high-wear applications (hardness up to 300 HB), suitable for gear teeth and bearing surfaces
• Isothermal annealing to reduce internal stress in large-diameter (≥200mm) components, minimizing distortion during subsequent machining by 0.05mm/m
Our OEM capabilities support clients from design to production:
• Engineering support: DFM analysis to optimize gating, risering, and mold design for complex features (e.g., undercuts, thin walls <5mm) using simulation software (MAGMAsoft) to predict and prevent defects
• Material customization: Grades from 60-40-18 (high ductility for shock-loading applications) to 120-90-02 (high-strength for heavy machinery) based on application requirements, with material certificates (PMI testing) provided
• Testing protocols: Ultrasonic inspection (for internal defects), magnetic particle testing (for surface cracks), and tensile testing with full traceability reports (batch-to-customer tracking)
• Production scalability: Volumes from 500 to 100,000+ units/year with lead times of 4-6 weeks for tooling (shell mold patterns) and 2-3 weeks for production, supported by 3 shifts operation
• Value-added services: Machining (CNC turning/milling), coating (epoxy, zinc plating), and assembly (bearing press-fit, seal installation) to deliver ready-to-install components, reducing client assembly time by 30%
