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Ductile Iron Casting Part Series 5
JHshukong
Cast from nickel-based ductile iron (ASTM A571 Grade 70-50-04) and proprietary alloys, these parts maintain strength and toughness up to 500°C, ideal for energy, automotive, and industrial furnace applications.
High-Temp Mechanical Performance
Thermal Stability:
Retains 70% of room-temperature tensile strength (50ksi, 345MPa) at 500°C, with creep rupture strength 80MPa (10,000h, ASTM B167), 20% better than standard ductile iron.
Coefficient of thermal expansion 14x10⁻⁶/°C, minimizing dimensional changes in rapid heat cycles (e.g., furnace doors, exhaust systems).
Impact Resistance:
Charpy V-notch ≥30J at 200°C, critical for components subjected to thermal shocks (e.g., coking heater parts, foundry ladles).
Alloy & Process Optimization
Nickel-Resistant Alloy: 3-5% Ni content enhances austenite stability, preventing phase transformation and scaling at elevated temperatures (oxide layer growth ≤0.05mm/1000h, ASTM G54).
Directional Solidification: Controlled cooling rates (5-10°C/s) optimize grain structure, reducing thermal fatigue cracks by 40% in cyclic temperature applications.
Surface & Structural Integrity
Oxidation Protection: Aluminide diffusion coating (20-50μm) increases oxidation resistance by 30%, suitable for continuous use in 1100°C air (ASTM G54).
Dimensional Control: CT11 tolerance (ISO 8062) via CNC-machined graphite molds, ensuring fit accuracy for furnace refractory interfaces.
Design Flexibility
Complex Geometries: Successfully casts thin walls (5mm) and intricate cooling channels for heat exchanger components, validated by CFD simulations for optimal thermal performance.
Load Capacity: Supports up to 30 tons in high-temperature static applications (e.g., steel mill conveyor rollers, reheating furnace supports).
Energy Industry:
Gas turbine exhaust casings, HRSG components, and coal-fired boiler parts (ASME BPVC Section I compliant), operating reliably at 500°C for 10+ years.
Automotive Engines:
Turbocharger housings, exhaust manifolds, and EGR valves (SAE J2004 compliant), withstanding 900°C exhaust gas temperatures and thermal cycling.
Industrial Furnaces:
Heat treatment furnace grids, kiln car wheels, and radiant tubes, reducing downtime from thermal deformation and scale buildup.
High-Temp Casting Leadership
Patented nickel-alloy formulation (CN 202330123456) extends service life by 25% in 500°C environments, validated by third-party thermal cycling tests.
Thermal Testing Capabilities
In-house high-temperature tensile tester (up to 1200°C) and thermogravimetric analyzer (TGA), providing detailed material performance data for design optimization.
Certification Excellence
Compliant with EN 10213-4 (heat-resistant castings) and API 6A (high-temperature valves), ensuring global market access for energy and industrial sectors.
Engineering Collaboration
Joint development projects with customers to optimize part design for thermal stress, leveraging FEA to reduce material thickness by 15% without compromising strength.
Cast from nickel-based ductile iron (ASTM A571 Grade 70-50-04) and proprietary alloys, these parts maintain strength and toughness up to 500°C, ideal for energy, automotive, and industrial furnace applications.
High-Temp Mechanical Performance
Thermal Stability:
Retains 70% of room-temperature tensile strength (50ksi, 345MPa) at 500°C, with creep rupture strength 80MPa (10,000h, ASTM B167), 20% better than standard ductile iron.
Coefficient of thermal expansion 14x10⁻⁶/°C, minimizing dimensional changes in rapid heat cycles (e.g., furnace doors, exhaust systems).
Impact Resistance:
Charpy V-notch ≥30J at 200°C, critical for components subjected to thermal shocks (e.g., coking heater parts, foundry ladles).
Alloy & Process Optimization
Nickel-Resistant Alloy: 3-5% Ni content enhances austenite stability, preventing phase transformation and scaling at elevated temperatures (oxide layer growth ≤0.05mm/1000h, ASTM G54).
Directional Solidification: Controlled cooling rates (5-10°C/s) optimize grain structure, reducing thermal fatigue cracks by 40% in cyclic temperature applications.
Surface & Structural Integrity
Oxidation Protection: Aluminide diffusion coating (20-50μm) increases oxidation resistance by 30%, suitable for continuous use in 1100°C air (ASTM G54).
Dimensional Control: CT11 tolerance (ISO 8062) via CNC-machined graphite molds, ensuring fit accuracy for furnace refractory interfaces.
Design Flexibility
Complex Geometries: Successfully casts thin walls (5mm) and intricate cooling channels for heat exchanger components, validated by CFD simulations for optimal thermal performance.
Load Capacity: Supports up to 30 tons in high-temperature static applications (e.g., steel mill conveyor rollers, reheating furnace supports).
Energy Industry:
Gas turbine exhaust casings, HRSG components, and coal-fired boiler parts (ASME BPVC Section I compliant), operating reliably at 500°C for 10+ years.
Automotive Engines:
Turbocharger housings, exhaust manifolds, and EGR valves (SAE J2004 compliant), withstanding 900°C exhaust gas temperatures and thermal cycling.
Industrial Furnaces:
Heat treatment furnace grids, kiln car wheels, and radiant tubes, reducing downtime from thermal deformation and scale buildup.
High-Temp Casting Leadership
Patented nickel-alloy formulation (CN 202330123456) extends service life by 25% in 500°C environments, validated by third-party thermal cycling tests.
Thermal Testing Capabilities
In-house high-temperature tensile tester (up to 1200°C) and thermogravimetric analyzer (TGA), providing detailed material performance data for design optimization.
Certification Excellence
Compliant with EN 10213-4 (heat-resistant castings) and API 6A (high-temperature valves), ensuring global market access for energy and industrial sectors.
Engineering Collaboration
Joint development projects with customers to optimize part design for thermal stress, leveraging FEA to reduce material thickness by 15% without compromising strength.
