Cast Iron Castings
Welcome to Bhanu Special Castings Pvt. Ltd. – your trusted partner for high-quality cast iron castings in Vijayawada and across India. As a leading cast iron foundry, we manufacture grey iron (EN-GJL-150 to EN-GJL-400), ductile iron/SG iron (EN-GJS-400-18 to EN-GJS-800-2), and specialized wear-resistant alloys (Ni-Hard, Hi-Chrome) delivering exceptional strength, vibration damping, wear resistance, and cost-effectiveness for automotive, machinery, pump, and industrial applications.
Cast iron castings are iron-carbon-silicon alloys (typically 2.5–4.0% C, 1.0–3.0% Si) where carbon appears as graphite flakes (grey iron), spherical nodules (ductile/SG iron), or combined as carbides (white iron alloys). Grey cast iron offers superior vibration damping (6–10× better than steel) ideal for machine tool bases, excellent thermal conductivity for engine blocks and brake discs, and outstanding machinability. Ductile iron provides steel-like tensile strength (400–800 MPa) with good ductility and fatigue resistance for gears and crankshafts. Ni-Hard and high-chrome white irons achieve extreme hardness (550–750 HB) for severe abrasion in mining and cement industries.
Our cast iron castings deliver exceptional performance: excellent castability for complex geometries, superior vibration damping in grey iron, high tensile strength and ductility in ductile iron, outstanding abrasion resistance in white iron alloys, excellent thermal properties, and cost-effective production. Manufactured to EN 1561 / EN 1563, ISO 185 / ISO 1083, ASTM A48 / A536 / A532 standards, they are ideal for machine bases and frames, automotive engine blocks and cylinder heads, pump housings and impellers, pipe fittings and manhole covers, and gear housings and counterweights. Advanced molding, melting, and testing ensure consistent quality.
Our Product Range
We manufacture diverse cast iron castings engineered for strength, vibration damping, and wear resistance:
- Machine Bases & Frames Lathe beds, milling machine bases, CNC machine frames, and precision foundations.
- Automotive Components Engine blocks, cylinder heads, flywheels, brake discs, and differential housings.
- Pump Housings & Components Centrifugal pump casings, submersible pump bodies, and impellers.
- Pipe Fittings & Covers Flanges, elbows, valves, manhole covers, and gully gratings.
- Gearbox Casings & Housings Industrial gear housings, motor frames, and compressor blocks.
- Counterweights Tractor, excavator, and crane counterweights in grey or ductile iron.
- Wear-Resistant Castings Ni-Hard and high-chrome castings for mining and cement crusher applications.
- Custom Cast Iron Castings Application-specific designs manufactured from customer drawings.
Weight Range: 0.5 kg to 8000 kg | Grades: Grey Iron (EN-GJL), Ductile Iron (EN-GJS), Ni-Hard / Hi-Chrome
Industry Applications
Our cast iron castings serve critical functions across demanding industrial sectors:
- Automotive & Heavy Vehicles Engine blocks, transmission housings, and suspension components.
- Machine Tool Industry Precision machine bases, CNC frames, and tool posts.
- Pumps & Compressors Water pumps, oil pumps, and air compressor housings.
- Construction & Infrastructure Manhole covers, drainage gratings, and pipe fittings.
- Agriculture & Tractors Tractor counterweights, plough frames, and harvester components.
- Mining & Material Handling Crusher wear parts, chutes, and conveyor components.
- Power Generation Generator housings, turbine casings, and valve bodies.
- General Engineering Motor housings, gearboxes, and custom industrial equipment.
Cast iron castings are manufactured using high-quality iron alloys, providing excellent castability, wear resistance, and dimensional stability. These castings are widely used in industries where strength, durability, and machinability are essential, making them ideal for applications such as machine bases, pipe fittings, automotive components, pump housings, and industrial machinery.
Key Properties & Benefits of Cast Iron Castings
Cast iron offers excellent castability and affordability, with properties tailored by grade: grey iron for damping and thermal conductivity, ductile iron for strength and toughness, and white irons (Ni-Hard, Hi-Chrome) for extreme abrasion resistance.
- Superior Vibration Damping Grey cast iron absorbs vibrations 6–10× better than steel — ideal for machine bases, frames, and precision equipment.
- Excellent Thermal Conductivity High heat dissipation reduces thermal stress in engine blocks, pumps, and rotating machinery.
- Outstanding Machinability Easier to machine than many steels, producing good surface finishes with reduced tool wear.
- High Wear & Abrasion Resistance Ni-Hard and high-chrome grades achieve 550–750 HB hardness for severe mining and cement applications.
- Cost-Effective Castability Complex shapes produced at lower cost with excellent fluidity for thin sections and large components.
- Grade-Specific Corrosion Resistance High-chrome variants offer improved resistance in wet and abrasive environments.
These characteristics make cast iron the preferred material for non-dynamic, high-stability, or wear-focused components — grey for damping, ductile for strength, white alloys for abrasion resistance.
Grades and Applications of Cast Iron Castings
Our cast iron castings are produced in globally accepted grades such as Grey Iron (EN-GJL-150 to EN-GJL-400 / ISO 185 / ASTM A48 Class 20–60), Ductile Iron (EN-GJS-400-18 to EN-GJS-800-2 / ISO 1083 / ASTM A536 60-40-18 to 120-90-02), Ni-Hard (ASTM A532 Class I), and High-Chrome White Iron (ASTM A532 Class III). Every grade is engineered for superior damping, wear resistance, strength, and machinability.
Major application areas include:
- Automotive & Heavy Vehicles: Cylinder blocks, cylinder heads, flywheels, differential housings, brake calipers.
- Industrial Machinery: Lathe beds, milling machine bases, press frames, gearbox casings.
- Pumps & Valves: Pump casings, impellers, gate/globe valve bodies (PN10–PN40).
- Mining & Cement: Jaw crusher side plates, hammer mill hammers, ball mill liners.
- Agriculture & Construction: Tractor/excavator counterweights, plough frames, structural components.
| Grade | Key Properties | Typical Applications |
|---|---|---|
| Grey Iron EN-GJL-150 to EN-GJL-400 (ASTM A48 Class 20–60) |
Excellent vibration damping (6–10× steel), high thermal conductivity, good machinability; tensile 150–400 MPa | Machine tool bases, compressor blocks, motor frames, engine blocks |
| Ductile Iron EN-GJS-400-18 to EN-GJS-800-2 (ASTM A536 60-40-18 to 120-90-02) |
High tensile strength (400–800 MPa), good ductility (2–18% elongation), fatigue resistance | Crankshafts, heavy-duty gears, suspension parts, wind turbine hubs |
| Ni-Hard (ASTM A532 Class I) | Hardness 550–650 HB, outstanding abrasion resistance | Slurry pump impellers, chute liners, shot-blast parts |
| High-Chrome Iron (ASTM A532 Class III) | Hardness 600–750 HB, extreme wear & corrosion resistance | Coal mill rollers, cement mixer blades, dredge pump parts |
Typical Composition & Properties (Grey Cast Iron Focus – EN-GJL / ASTM A48)
| Element / Property | Typical Range / Value | Notes (Grey Iron; White Alloys Vary) |
|---|---|---|
| Carbon (C) | 2.5–4.0% | Higher promotes graphite flakes in grey; carbides in white |
| Silicon (Si) | 1.0–3.0% | Graphite stabilizer; 2.5–2.8% typical for grey |
| Manganese (Mn) | 0.5–1.0% | Strengthens matrix |
| Phosphorus (P) | 0.1–0.9% | Improves fluidity; low in high-strength grades |
| Sulfur (S) | ≤0.15% | Low to avoid brittleness |
| Tensile Strength | 150–450 MPa (Class 20–60) | No defined yield (brittle in tension); higher in ductile grades (400–800 MPa) |
| Compressive Strength | 570–1290 MPa | Excellent under compression |
| Hardness (Brinell) | 160–300 HB (grey); 550–750 HB (white irons) | Grey: machinable; White: extreme wear |
| Thermal Conductivity | High (better than steel) | Excellent heat dissipation |
| Density | 7.1–7.3 g/cm³ | Similar across types |
Values typical for grey cast iron (EN-GJL-150 to EN-GJL-400 / ASTM A48 Class 20–60); ductile/white irons differ (higher strength in EN-GJS, extreme hardness in Ni-Hard/High-Chrome). Custom compositions available.
Advanced Cast Iron Manufacturing Process
At Bhanu Special Castings, our cast iron foundry employs green sand molding, shell molding, and resin-bonded processes with cupola/induction furnace melting to produce high-quality grey, ductile, and white iron castings.
1. Pattern & Mold Design
Wooden/aluminum pattern making, green sand or resin-bonded molding, core assembly for complex internal geometries.
2. Melting & Composition Control
Cupola/induction furnace melting at 1350–1450°C, precise C-Si control for grey vs. white structure, nodularization (Mg addition) for ductile iron.
3. Pouring & Solidification
Temperature-controlled pouring, cooling rate management for graphite formation (grey) or carbide retention (white), shakeout and cleaning.
4. Heat Treatment (If Required)
Stress relieving at 550–650°C for dimensional stability, annealing for improved machinability, quenching/tempering for white iron wear parts.
5. Machining & Finishing
CNC machining for critical dimensions, shot blasting for surface cleaning, painting/coating per specifications.
6. Quality Testing
Tensile/hardness testing per grade, graphite structure / nodularity examination, NDT (UT/MT), dimensional verification.
Customization and Quality Assurance
We provide fully customized cast iron castings — grey, ductile, or white iron alloys — with pattern making, precision machining, and finishing per your exact specifications. Our Vijayawada team ensures every casting meets dimensional tolerances, mechanical properties, and international standards.
Customization Capabilities
- Grade selection (grey EN-GJL-150 to 400, ductile EN-GJS-400-800, Ni-Hard/Hi-Chrome)
- Pattern development (wood, aluminum, 3D-printed)
- Complete CNC machining and assembly services
- Surface treatments (painting, powder coating, electroplating)
- Reverse engineering from worn or damaged parts
- Weight range: 0.5 kg to 8000 kg single piece
Quality Testing & Certifications
- Chemical Analysis Verification of C, Si, Mn, P, S per specified grade
- Mechanical Testing Tensile strength, hardness, impact testing per EN/ASTM
- Metallographic Examination Graphite morphology, nodularity %, matrix structure analysis
- Non-Destructive Testing (NDT) Ultrasonic (UT), Radiographic (RT), Magnetic Particle (MT)
- Dimensional Inspection CMM-based precision measurement
- EN / ASTM / ISO Compliance Full material certification and traceability
Why Choose Bhanu Special Castings for Cast Iron?
With decades of specialized cast iron foundry experience serving automotive, machine tool, and industrial sectors, we deliver consistent quality, competitive pricing, and reliable delivery. Here's why industry leaders trust us:
Complete Foundry Capability
Grey, ductile, and white iron production under one roof with green sand, resin-bonded molding, and precision machining.
Automotive Industry Approved
Trusted supplier for engine blocks, cylinder heads, brake components — meeting stringent automotive quality standards.
Machine Tool Specialists
High-quality grey iron machine bases with superior damping for CNC, lathe, and milling machine manufacturers across India.
Large Casting Capability
Up to 8-ton single-piece castings for heavy machinery, counterweights, large pump housings, and structural components.
In-House Testing Lab
Complete metallurgical laboratory with tensile testing, hardness verification, graphite/nodularity analysis, and NDT capabilities.
Customer Partnership
Design support, pattern storage, vendor-managed inventory, and responsive technical assistance for long-term partnerships.
Frequently Asked Questions (FAQ)
Ready for Durable Cast Iron Castings?
Get in touch with our Vijayawada team for custom designs, fast quotes, and ISO-certified quality you can trust.
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