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2020 China New Design Duplex Stainless Steel Casting - Shell Mold Casting of Ductile Cast Iron – RMC Foundry

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2020 China New Design Duplex Stainless Steel Casting - Shell Mold Casting of Ductile Cast Iron – RMC Foundry Detail:

China OEM custom spheroidal graphite cast iron part by shell mold casting products with CNC machining, heat treatment and surface treatment. 

 

Mechanical Properties of Ductile (Nodular) Cast Iron 

Item according to DIN EN 1563 Measure Unit EN-GJS-350-22-LT EN-GJS-400-18-LT EN-GJS-400-18 EN-GJS-500-7 EN-GJS-600-3 EN-GJS-700-2 EN-GJS-800-2
EN-JS 1015 EN-JS 1025 EN-JS 1020 EN-JS 1050 EN-JS 1060 EN-JS 1070 EN-JS 1080
Tensile Strength Rm min.MPA 350 400 400 500 600 700 800
2% Yield Strength Rp0.2 min.MPA 220 240 250 320 370 420 2) 480 2)
Elongation A % 22,0 18,0 18,0 7,0 3,0 2,0 2,0
Hardness HB 110-150 120-160 140-190 170-220 200-250 230-280 250-330
Structures   mainly ferritic mainly ferritic mainly ferritic ferritic + pearlite ferritic + pearlite mainly pearlite all pearlite
Shear Stress σaB MPa 315 360 360 450 540 630 720
Torsion TtB MPa 315 360 360 450 540 630 720
Modules of elasticity E GPa 170 170 170 175 175 175 175
Poisson number v – 0,280 0,280 0,280 0,280 0,280 0,280 0,280
Compressive Strength σdB MPa 700 700 800 870 1000 1150
Frature Toughness Klc MPa ·√m 31 30 30 25 20 15 14
Density g/cm3 7,1 7,1 7,1 7,1 7,2 7,2 7,2

 

Shell molding casting process is also called pre-coated resin sand casting process, hot shell molding castings or core casting process. The main molding material is the pre-coated phenolic resin sand, which is more expensive than green sand and furan resin sand. Moreover, this sand can not be recycle used. 

Furan resin self-hardening sand casting process (nobake process) uses the furan resin coated sand to form the casting mold. After mixing the original sand (or reclaimed sand), liquid furan resin and liquid catalyst evenly, and filling them into the core box (or sand box), and then tighten it to harden into a mold or mold in the core box (or sand box) at room temperature. Then the casting mould or casting core were formed, which is called self-hardening cold-core box molding (core), or self-hardening method (core).

Because the mold is formed at room temperature and no need to heat, the self-hardening sand casting is also called no-bake casting process. The self-hardening method can be divided into acid-catalyzed furan resin and phenolic resin sand self-hardening method, urethane resin sand self-hardening method and phenolic monoester self-hardening method.

As a self-hardening cold box binder sand, furan resin sand is the earliest and currently most widely used synthetic binder sand in Chinese foundry. The amount of resin added in molding sand is generally 0.7% to 1.0%, and the amount of added resin in core sand is generally 0.9% to 1.1%. The content of free aldehyde in furan resin is below 0.3%, and some factories have dropped to below 0.1%. In the foundries in China, the furan resin self-hardening sand has reached the international level regardless of the production process and the surface quality of the castings.

Ductile cast iron, which is also called nodular cast iron, spheriodal graphite cast iron or just SG iron for short, represent a group of cast iron. Nodular cast iron obtains nodular graphite through spheroidization and inoculation treatment, which effectively improves the mechanical properties of the cast iron, especially the plasticity and toughness, so as to obtain higher strength than carbon steel.

Ductile iron castings have better shock absorption performance than carbon steel, while carbon steel castings have much better weldability. And to some extent, the ductile iorn castings could have some performances of resistanting wear and rust. So the ductile iron casting could be used for some pump housings or water supply systems. However, we still need to make precautions for protecting them from wearing and rust.

Ductile iron is not a single material but is part of a group of materials which can be produced to have a wide range of properties through control of the microstructure. The common defining characteristic of this group of materials is the shape of the graphite. In ductile irons, the graphite is in the form of nodules rather than flakes as it is in grey iron. The sharp shape of the flakes of graphite create stress concentration points within the metal matrix and the rounded shape of the nodules less so, thus inhibiting the creation of cracks and providing the enhanced ductility that gives the alloy its name. So generally speaking, if the ductile iron could meet your requirements, the ductile iron could be your first choice, instead of carbon steel for your castings.

Nodular Grade of Ductile Cast Iron

 

Resin Coated Sand Casting Metal and Alloys
Metal & Alloys Popular Grade
Gray Cast Iron GG10~GG40; GJL-100 ~ GJL-350; 
Ductile (Nodular) Cast Iron GGG40 ~ GGG80; GJS-400-18, GJS-40-15, GJS-450-10, GJS-500-7, GJS-600-3, GJS-700-2, GJS-800-2
Austempered Ductile Iron (ADI) EN-GJS-800-8, EN-GJS-1000-5, EN-GJS-1200-2
Carbon Steel C20, C25, C30, C45
Alloy Steel 20Mn, 45Mn, ZG20Cr, 40Cr,   20Mn5, 16CrMo4, 42CrMo,
40CrV, 20CrNiMo, GCr15, 9Mn2V
Stainless Steel Ferritic Stainless Steel, Martensitic Stainless Steel, Austenitic Stainless Steel, Precipitation Hardening Stainless Steel, Duplex Stainless Steel
Aluminium Alloys ASTM A356, ASTM A413,  ASTM A360
Brass / Copper-based Alloys C21000, C23000, C27000, C34500, C37710, C86500,  C87600, C87400, C87800,  C52100, C51100
Standard: ASTM, SAE, AISI, GOST, DIN, EN, ISO, and GB

 

The Advantages of Furan Resin Coated Sand Self-hardening Molding Casting:
1) Improve the dimensional accuracy of castings and the surface roughness.
2) The hardening of the mold (core) sand does not require drying, which can save energy, and inexpensive wood or plastic core boxes and templates can also be used.
3) Self-hardnening molding sand is easy to compact and collapse, easy to clean up castings, and old sand can be recycled and reused, which greatly reduces the labor intensity of core making, modeling, sand falling, cleaning and other links, and it is easy to realize mechanization or automation.
4) The mass fraction of resin in sand is only 0.8%~2.0%, and the comprehensive cost of raw materials is low.

Because the self-hardening method has many of the above-mentioned unique advantages, the self-hardening method is not only used for core making, but also used for casting moulding. It is especially suitable for single piece and small batch production, and can produce cast iron, cast steel and non-ferrous alloy castings. Some Chinese foundries have completely replaced clay dry sand molds, cement sand molds, and partially replaced water glass sand molds.

Resin Coated Sand Shell Casting Factory

Ductile Iron GGG50 Parts
custom shell mold casting product

Ductile Cast Iron Parts

ductile iron casting products

Ductile Iron Castings


Product detail pictures:

2020 China New Design Duplex Stainless Steel Casting -
 Shell Mold Casting of Ductile Cast Iron – RMC Foundry detail pictures

2020 China New Design Duplex Stainless Steel Casting -
 Shell Mold Casting of Ductile Cast Iron – RMC Foundry detail pictures

2020 China New Design Duplex Stainless Steel Casting -
 Shell Mold Casting of Ductile Cast Iron – RMC Foundry detail pictures


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