What are Cast Iron Parts, Their Manufacturing Process
Cast iron is iron that includes a small quantity of carbon. It is firm and cannot be bent, so it needs to be made into different parts by casting. So, this kind of iron casting is known as cast iron parts. These parts are components manufactured from cast iron, iron alloy, carbon, and various elements, which are made by flowing molten iron into molds to strengthen. These parts are recognised for their sturdiness, heat resistance, and ability to be designed into complicated forms. They are broadly used in different industries because of their durability, affordability, and machinability.
Conventional Manufacturing Process for Cast Iron Parts
Cast iron is a common kind of casting. And the most generally used manufacturing process for this type of part is the sand casting procedure.
Sand casting is one of the casting procedures where the molten metal is drained into a mold made of sand. There are different types of sand casting, such as resin sand casting, precast sand casting, and green sand casting. Sand casting is always preferred to make parts of cast grey iron or ductile iron due to the cost-efficiency of the procedure and the easy accessibility of raw materials.
Industries that Rely Heavily on Cast Iron Parts
Metal casting processes have become pivotal to various industrial operations, as it is by these processes that power-efficient customised metal goods are manufactured at scale. Here, we are sharing some of the industrial segments that rely most on cast iron parts.
1. Automobile
Cast iron parts are essential constituents in automobiles. While several parts are made with cast iron, the engine block should be made of premium-quality cast iron or aluminium alloy. These parts increase the reliability and performance of the car, as the engine includes the primary components that make up an automobile’s base.
Apart from aluminium and iron casting, manufacturers also use die castings manufactured of zinc and magnesium to make secure, clean vehicles that take up less fuel and discharge less harmful gases. Thus, the casting industry plays an important role in the automobile niche while helping save energy and ensuring safety.
2. Marine
Working in the marine industry signifies contending with harmful surroundings at sea and in ports. From the highest temperatures, heavy rains, and swells, there is a requirement to stay safeguarded at all times. The casting industry makes a variety of quality, protected metal goods for the marine industry.
Some of the key metals employed in the marine industry are aluminium, stainless steel, and alloys. The most common alloys utilised for cast marine-grade products include bronze, copper, and aluminium. Copper alloys are normal in propellers, valves, piping, heat tubing, and pumps. These alloys are specifically applicable as they are simple to make, sturdy, and have increased thermal conductivity. Moreover, there is less possibility of marine animals being linked to copper. Various alloys can be used to make other parts, and the power of these alloys can be improved with the addition of zinc.
3. Construction
The construction industry is also much reliant on cast iron parts. Cast iron is very durable, which is why it is normally used in building and construction activities.
Castings are normally used for basic constituents such as columns and bases. They are also utilised in manhole covers and utility holes, gates, and cisterns. Cast iron is also employed in the manufacturing of pipes as it is corrosion-proof and has outstanding tensile and compressive strength. Additionally, it is used in bridges, buildings, and long-standing structures due to its amazing load-bearing capacities.
4. Oil, Gas and Mining
Casting has various uses in the mining industry. The most common metal in the oil, gas, and mining industry is alloyed cast iron. It has been employed to manufacture wheel hubs and clamping rings for shakers and trucks, crushers, and piston shafts. Cast iron is utilised here for its trustworthiness and flexibility.
Provocatively, the mining and casting industries are highly interdependent. The casting industry depends on the iron industry to get the needed metals, while the mining industry relies on the casting industry for cast iron parts and accessories. Consequently, cast iron ensures minimum wear and tear and mechanical exhaustion, which offers value for money and financial efficiency.
5. Military and Defence
Think about military vehicles, gear, and firearms. These can sustain the most rigid conditions, thanks to cast structures. While some machines cannot stay for long periods without use, military devices can stay in use for a long time and still attain peak performance.
Cast iron parts in military and defence involve spare parts, trigger guards, pistol grips, hammers, joysticks for drone planes, sights and gun triggers. Besides the military parts being long-lasting, they are also economical and can be made faster and more accurately because of the use of cast metals.
6. Aviation
Titanium, steel, aluminium, and their alloys are all employed in aviation. Aluminium alloys have reduced density values compared to steel alloys and have effective corrosion resistance. Aluminium is also utilised to create fixtures like doors, seats, and cabinetry.
Steel is one more key aviation metal. Known for its resistance to increased temperatures, durability, and hardness, it is used to prepare parts like hinges, aircraft skin, fasteners, and cables.
7. Agriculture
The agricultural industry is liable for offering food on our tables. Moreover, the sector requires agricultural tools to work in exhausting conditions. Investment casting is one of the most prominent manufacturing procedures for producing cast metals for the agriculture industry. Investment casting works as it can yield results in a short time, reduces waste, and is efficient and inexpensive. Therefore, manufacturers can produce sturdy machines that can resist heavy agricultural uses.
Cast metals employed for agriculture need to be able to work in the most severe environmental conditions, and investment casting assures the parts are powerful, detailed, and have a long life span. Parts made from this procedure are also corrosion-proof and have an increased load-bearing capacity, which is essential when in the field. Moreover, investment casting is costly, allows for quicker production, and is effortless for the agricultural industry.
Final Words
As you can understand, iron casting has uses in various industries. Without it, the world would not be as it is today in the sense of machinery, and if it were, it would signify that everything from the parts to the finished goods would be more costly. Thus, if you are searching for the best cast iron parts for your specific industrial use, you must work with a manufacturer like AKP Ferrocast that very well knows the science of iron casting.
