Please go through the some basic information about the raw material which we use and also the technical aspect of our work. Here we have covered the standards which we follow [ IS:210-2009 ] and also its equivalent international standards. Since the casting have very vast application, we are well equipped to make Gray Iron casting weighting from 2lbs to 220lbs [ 1 Kgs to 100 kgs ] with green sand casting & No Back casting process. In Shall Molding we can make the castings weighting from 2lbs to 55lbs (1 Kgs to 25 Kgs) deepening upon the job.
Grey Cast iron, also known as flake graphite cast iron, is a type of type of cast iron in which most of the carbon is present as flake graphite corresponding to form I of IS 7754. The properties of Grey Cast Iron depends on the distribution, size and amount of graphite flakes, and the matrix structure. These factors are in turn, influenced mainly by the manufacturing conditions, chemical composition, solidification time and rate of cooling in the mould. Grey cast iron exhibit low to moderate strength, low modulus of elasticity, low notch sensitivity, high thermal conductivity, moderate resistance of thermal stock, and outstanding castability.
In general, the following properties of grey cast iron increases with increasing tensile strength.
On the other hand, the following properties decreases with increasing tensile strength
We have state of art tooling & jig Fixtures making division. In that we make all our tooling and jig fixtures with very less time as per 3D model designs. The general time duration for casting developments is 14-21 days but it can vary depending upon the job. We have made sure that our engineers best in the industry , so as to climb the very first step successfully.
Moulding / Core Process 1. Resin Coted or Shell Molding Sand
2. Two Part Furan No Bake Sand
3. Green Sand
Shell mould casting process offers better surface finish, better dimensional tolerance, and higher throughout due to reduced cycle time. A heated [200 oC - 375 oC] metal pattern is covered with a mixture of sand and thermoset plastic. This causes a skin of about 3.5 mm (0.125 in) of sand/plastic mixture to adhere to the pattern. This skin is removed from the pattern to form the "shell mold". This process can produce complex parts with good surface finish 1.25 um to 3.75 um (50 uin to 150 uin) rms, and dimensional tolerance of 0.5%. Size limit of 1 kg to 25 kg. Minimum thickness can be as low as 1.5mm (0.062 in) to 6.25mm (0.25 in), depending on the material. A good surface finish and good size tolerance reduce the need for machining. A fairly high capital investment is required, but high production rates can be achieved. The process overall is quite cost effective due to reduced machining and cleanup cost. The general casting tolerance is IS +/- 1/32" to 1/16" per inch. The surface roughness is 250 RMS to 500 RMS.
Once Tooling for casting is ready, it takes about 5-10 days for submitting samples, however The factors which affect time duration is size of casting, process involved, quality requirements and machining.
Once the sample is approved, we start production, general time take for the first production batch delivery is between 25 to 30 days depending upon the casting and quantity of the First batch
To get most competitive price , it is suggested to give minimum order for one full container load.
| IS - 210 - 93 IS6331 -87 |
ASTM A-48-94a |
BS 1452-90 |
DIN-1691-85 | GOST 1412-85 | ISO-185-88 | JIS-G5501-89 | SAE J431-93ASTM A159-83 |
| FG 150 | 25B | 150 | GG-15 | C415 | 150 | FC150 | G2500 |
| FG 200 | 30B | 200 | GG-20 | C420 | 200 | FC200 | G3000 |
| FG 220 | 35B | 220 | - | C424 | - | - | G3500 |
| FG 260 | 40B | 250 | GG-25 | C425 | 250 | FC250 | G4000 |
| FG 300 | 45B | 300 | GG-30 | C430 | 300 | FC300 | - |
Grade |
Typical Application |
| FG 150 | Andirons, exhaust manifolds, frames, grates, housings, machine bases, manhole covers |
| FG 200 | Air-cooled cylinders, clutch housings, clutch plates, compressor frames, cylinder heads, flywheels, gearboxes, grate bars, impellers, light-duty brake drums, oil pump bodies, pipe and fittings,rams small cylinder blocks, and transmission cases |
| FG 220 | Air cooled Cylinders, clutch housings, clutch plates, compressor frames, cylinder heads, flywheels gear boxes, grate bars, impellers light-duty brake drums, oil pump bodies, pipe and fittings, pistons, rams, small cylinder blocks, and transmission cases. |
| FG 260 | Anvils, automobile and diesel cylinder blocks, compressors, cylinder heads, cylinder liners, face plates, heavy flywheels, heavy machine beds, impellers, medium-duty brake drums and clutch plates, pistons, pumps, rams, steam pressure castings, valves and wheels |
| FG 300 | Anvils, brake drums and clutch plates for heavy-duty service, compressors, diesel engine blocks, differential carrier castings, face plates, heavy flywheels, heavy gearboxes, heavy machine beds, impellers, pumps, rams, steam pressure castings, tractor transmission cases, truck and tractor cylinder blocks and heads valves, and wheels. |
| Property | Unit | FG150 | FG 200 | FG 220 | FG 260 | FG 300 |
| Tensile Strength | MPa | 150 | 200 | 220 | 260 | 300 |
| 0.01 % Proof Stress | MPa | 42 | 56 | 62 | 73 | 84 |
| 0.10 % Proof Stress | MPa | 98 | 130 | 143 | 169 | 195 |
| Total strain at failure | % | 0.60-0.75 | 0.48-0.67 | 0.39-0.63 | 0.57 | 0.50 |
| Elastic strain at failure | % | 0.15 | 0.17 | 0.18 | 0.20 | 0.22 |
| Total minus elastic strain at failure | % | 0.45-0.60 | 0.31-0.50 | 0.21-0.45 | 0.37 | 0.28 |