Cast iron, an alloy of iron and carbon with a carbon content above 2%, is one of the most widely used materials in the production of industrial components. By adding alloying elements such as manganese, chromium, nickel, or molybdenum, alloy cast irons with advanced mechanical properties, high corrosion resistance, and superior heat resistance can be produced. These alloys are extensively used in industries such as machinery, oil and gas, automotive, and power generation.
Excellent castability and precise shaping capability
High resistance to wear, corrosion, and heat
Suitable mechanical properties such as strength and toughness
Relatively low production cost
High dimensional stability at elevated temperatures
Graphite flakes in the microstructure
High damping capacity and vibration absorption
Commonly used in engine blocks, brake discs, and dynamic components
Combination of graphite and pearlite
High strength and wear resistance
Ideal for parts subjected to mechanical stress
Spheroidal graphite structure
High impact resistance and ductility
Applications: pressure pipes, gears, shafts
Semi-spheroidal compacted graphite
Better thermal resistance and improved heat conductivity
Used in diesel engines and industrial turbines
Designed for corrosive and high-temperature environments
Applications: steam industry parts, valves, oil and gas equipment
Selection of Raw Materials
Pig iron, alloying additions such as:
Manganese: increases hardness and controls graphitization
Nickel & Chromium: improve corrosion resistance and thermal stability
Melting and Homogenization
Performed in electric arc or induction furnaces for uniform composition
Chemical Inoculation
Addition of silicon or magnesium to refine graphite structure and prevent porosity
Pouring into Molds
Sand molds or permanent molds depending on alloy type and production volume
Solidification and Cooling
Controlled cooling to prevent cracks and porosity
Shakeout and Finishing
Removing sand, cleaning, machining, heat treatment, and quality inspection
| Property | Description |
|---|---|
| Graphitic Structure | Controlled graphite improves resistance |
| Mechanical Strength | Suitable for static and dynamic loads |
| Thermal Stability | High tolerance at elevated temperatures |
| Corrosion & Wear Resistance | Suitable for harsh environments |
| Economic Cost | Affordable raw materials and molding process |
Gas Porosity: absorption of hydrogen → degassing treatment
Shrinkage Cavities: insufficient feeding → optimized riser and gating design
Hot or Cold Cracks: rapid cooling or thermal stress → controlled cooling rates
Graphite Flakes / Surface Defects: improper chemistry → alloy adjustment
Automotive & Engine Components: cylinder blocks, liners, engine mounts (nodular iron, CGI)
Oil, Gas & Petrochemical: valves, gear housings, compressor casings (chromium-alloyed iron)
Heavy Machinery & Mining: gears, pump bases, wear-resistant parts
Power Plants & Turbines: heat-resistant housings, pump bodies, high-pressure components
Solidification Simulation: predicting cracks and defects
3D Modeling & Metal Printing: rapid mold and prototype production
CNC Machining: achieving tight tolerances post-casting
Process Automation: higher quality and repeatability in molding and melting
Choosing the right alloy based on functional requirements
Optimized mold, gating, and feeder system design
Controlled temperature, chemical composition, and cooling rate
Non-destructive testing (NDT) such as ultrasonic inspection, toughness testing, metallography
Alloy cast iron casting, thanks to its flexibility, mechanical strength, and durability, remains one of the cornerstones of modern industrial manufacturing. Success depends on precise alloy composition, optimized design, strict process control, and adoption of advanced technologies.
Peyman Nou Industrial Group, with extensive expertise in aluminum and alloy cast iron casting, is capable of producing high-quality, precise, and durable industrial components for a wide range of applications.
