Our Founding Process

See how cast iron is made

From CAD to the Product

How a Part is Made in our Foundry

For every casted part a model is required. This model is not equal to the final end product. It has a larger dimension to compensate the shrinkage when the material cools down. Sand forms are made from this model.

The Melting Process of Gray Cast Iron (GJL), Spheroidal Graphite Iron (GJS) and Ni-Resist (GGL-NiCuCr 15 6 3)

Casting iron isn't as easy as it seems: It is physically demanding and demands expert knowledge in the metallurgy of every employee.

With our process equipment we can cast the following qualities:

  • Ductile iron
  • Lamellar graphite cast iron
  • Ni-Resist

Induction furnances of our foundry heat up the raw materials for the casting. (Raw iron, steel crap, cast iron scrap and circulation material from the foundry) DC is applied to a water cooled induction coil. That induces eddy current in the material. This process draws a lot of Ampere—but it is fast and efficient.

Before finishing a small sample is taken for analysis. This is done by spectral analysis. The material from the sample is vaporized by a plasma in a inert gas chamber. The photons fly through a prism and splitted on the rear wall of the chamber. The spectral analysis has optoelectronic elements at this area to measure the intensity of every characteristic wavelenght. A computer calculates this intensity very accurate to a percentual value for every element (C, Si, Mn, Cr, Ni, Mo, Cu, etc.). With this value the skilled staff in the foundry can correct the melted metal with targeted addition.

When the cast iron reaches a temperature of approx. 1400 ° C–1500 ° C (2552 ° F–2732 ° F) a hydraulic mechanism tip the furnance out. A worker in our foundry casting iron.
Founder cast the liquid iron into the prepared sand molds. When the molds are cooled down the sand mold is putted on a riddle screen and the cast iron part appears.