Casting & Metallurgy

Casting and metallurgy materials form the backbone of modern industry. From iron and steel foundries to cement plants, mining facilities to surface treatment workshops, countless sectors depend on the correct sourcing and application of these materials. This guide comprehensively examines seven core material families for foundry buyers and metallurgical engineers.

Ferro Alloys: Ferro alloys are indispensable additives in steel and cast iron production. FeSi75 (72-78% Si) is used for deoxidation and silicon adjustment, while FeMn78 (78% Mn) is a critical alloying element for manganese steels. FeCr (60-72% Cr) serves as the chromium source in stainless steel production. FeSiMg (5-10% Mg) is used as a nodulizer in spheroidal graphite cast iron (SGCI) production. FeSiMn (65% Mn, 17% Si) provides combined deoxidation and alloying. Particle size for each ferro alloy (0-3 mm, 3-10 mm, 10-50 mm, 10-80 mm) is determined by the application method.

Pig Iron: Pig iron is the primary charge material for iron foundries. Hematite pig (3.8-4.2% C, low P and S) is ideal for grey and ductile iron. Steel pig (low carbon) is used as charge material in electric arc furnaces. SG pig (high purity, low Ti and Mn) offers superior mechanical properties in ductile iron applications. Carbon equivalent, phosphorus content and trace elements are critical parameters in pig iron selection.

Iron Casting Materials: Inoculants (FeSi-based, with 1-4% Ba, Ca or Sr additions) control graphite nucleation in cast iron and prevent chill formation. Nodulizers (FeSiMg with rare earth additions) convert free graphite to spheroidal form, enabling ductile iron production. Inoculant grain size (0.2-0.7 mm for ladle, 1-3 mm for in-stream) is selected based on the treatment point.

Non-Ferrous Casting Materials: For aluminum and copper foundries, we supply graphite crucibles (SiC-bonded, 1600°C resistance), tablet alloys (AlTi5B1, AlSr10 grain refiners and modifiers) and flux materials. Tablet alloys enhance casting quality by enabling precise chemical composition control.

Steel Shot and Casting Granules: Steel shot (S110-S780, 40-55 HRC) and steel grit (G10-G120) for shot blasting and surface preparation are manufactured in compliance with ISO 11126. B2/B3 alloy steel balls serve as grinding media in cement and mining mills. Hardness, impact resistance and microstructural homogeneity are fundamental quality parameters.

Silica Sand (Foundry Sand): Silica sand for molding and core-making is supplied in the AFS 45-55 grain fineness number range. Washed and dried sands with SiO₂ content above 98% offer low thermal expansion and high refractoriness. Grain shape (angular/round), acid demand value and loss on ignition are critical parameters affecting casting quality.

Forged Mill Balls: Forged balls made from 60Mn and 60MnCr grades, used in ball mills at cement, mining and mineral processing plants, are produced at 58-65 HRC hardness. Supplied in diameters from 20 mm to 150 mm, they deliver high impact toughness and wear resistance for extended mill life. Size distribution and metallurgical homogeneity are decisive for optimum grinding efficiency.

Material Selection Guide: Correct material selection depends on the casting process, target mechanical properties and cost objectives. For grey iron: hematite pig + FeSi75 inoculant combination; for ductile iron: SG pig + FeSiMg nodulizer; for steel casting: low-carbon FeMn + FeSi deoxidizers. In shot blasting, surface roughness requirements determine shot size, while in foundry sand selection, metal temperature and mold complexity determine the AFS number.