Grenzebach will choose the ideal casting process and the materials for your casting part.

Casting processes and casting materials for your casting part

Together with you, we choose the appropriate casting process for your component – from sand casting to chill casting to investment casting. Our vast range of manufacturing processes and casting materials provides you with the highest possible flexibility, speed and quality. For years, we have been working with several foundries in China, universities and the professional world – to produce castings tailored to your requirements.

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Optimal casting processes for your castings

MANUFACTURING PROCESSES

Sand casting

At the core of the sand casting process is a mold made of resin sand or green sand, which is used only once. This casting process is ideal for cast iron and other metallic materials. With or without a cavity, large or small – sand casting offers you maximum flexibility.

Advantages of this process:

  • Freedom in design
  • Independent of size
  • Moderate costs for patterns or setup

Chill casting

At the center of the permanent mold casting process is the permanent metal mold die in which the molten metal is poured. Gravity alone creates the mold filling. Due to the high thermal conductivity of the permanent mold, the melt cools down faster in the permanent mold casting process. The advantage for you: a denser and more homogeneous casting.

Advantages of this process:

  • High dimensional accuracy, less post-processing
  • Surface quality
  • Good contour reproduction

Pressure die casting

Pressure die casting is based on a metal mold that can be reused multiple times. In low- and high-pressure die casting, the molten metal is pressed into the metal mold under pressure. This process is especially effective in series production for thin-walled aluminum components.

Advantages of this process:

  • Fast
  • High casting quality
  • Thin-walled components possible

Investment casting

Investment casting, also known as lost-wax casting, excels through high design freedom and dimensional accuracy. Investment casting works with “lost” wax patterns which are treated with ceramic slurry. Investment casting is particularly suitable for small and very tiny parts.

Advantages of this process:

  • No separation of molds
  • Freedom in design
  • High dimensional accuracy and surface quality
  • Less effort for post-processing

Hot mold forging

In addition to the classic casting processes, Grenzebach also offers the hot mold forging process for components that require particular robustness and high load capacity. Semi-finished products are heated and shaped under pressure during the forging process. The heated metal is formed, sometimes in several steps, until the desired final contour is achieved.

Advantages of this process:

  • High strength
  • Generally good mechanical properties
  • No hardening, high formability
CHR Changjian Huaxin Robot Parts Nantong Co. Ltd, which Grenzebach has invested in, manufactures for renowned companies of the industry.

Cooperation with foundry

Grenzebach has been supporting the industry with casting parts for years and successfully works together with Chinese foundries. With our investment in the CHR Changjian Huaxin Robot Parts Nantong Co. Ltd foundry, we are further advancing casting. The team in Nantong produces castings for well-known companies in the robotics and automation industries. They focus on iron castings, gray cast iron as well as nodular cast iron.

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50 g - 17,000 kg

From filigree to very heavy: we can produce castings in all weight classes.

14,000 tons

of castings are manufactured and processed every year.

Our casting materials

Portfolio

Grenzebach’s product portfolio includes cast iron, gray cast iron or nodular cast iron.

Cast iron

Cast iron is an iron-carbon alloy with at least 2% carbon content that can be easily cast. The casting material occurs in two types among others:

  • Gray cast iron (EN-GJL)
  • Nodular cast iron (EN-GJS)

Gray cast iron has good machinability, vibration damping and wear resistance. Nodular cast iron is known for its high strength, elasticity, and heat resistance.

Steel casting has good welding properties.

Steel casting

Steel casting consists of an iron-carbon alloy with a carbon content of less than 0.5%.
The material for steel casting requires a higher melting temperature and is therefore more elaborate to cast than other casting materials.
Customers benefit from

  • High strength
  • Good welding properties
  • Support of multiaxial loads
Aluminum casting is highly formable and machinable.

Aluminum casting

Aluminum casting is very versatile, as it can be formed and machined easily due to its low density. The optimum casting properties of aluminum castings make them particularly suitable for the die casting process. It also provides

  • Thermal and electrical conductivity
  • Corrosion resistance
  • Weight reduction
Casting is a craft.

“Foundry is a craft – and that’s where we gain a lot of experience together with our customers and partners. Since I entered the foundry business professionally after studying foundry engineering at Lanzhou University, I’ve continued to learn every day – for 25 years. Our knowledge and network are the basis for casting products of the highest quality.”

 

Thomas Liu Grenzebach
Thomas Liu Director Casting Center at Grenzebach Machinery (Jiashan) Ltd.

Castings – a perfect fit and fully compliant with standards

Working with international standards is a matter of course for us. Thus, we implement the following framework in detail:

  • ISO 8062-3: Geometrical product specifications
  • DIN EN 1369: Founding – Magnetic particle testing
  • DIN EN 1559: Founding – Technical conditions of delivery – Parts 1 – 4
  • DIN EN 1370: Founding – Examination of surface condition
  • DIN EN 1561: Founding – Grey cast iron
  • DIN EN 1563: Founding – Spheroidal graphite cast irons
  • DIN EN 1706: Aluminum and aluminum alloy castings – Chemical composition and mechanical properties
  • DIN EN 12680: Founding – Ultrasonic examination
  • DIN EN 12681: Founding – Radiographic testing

Find out more about castings

The casting part is further processed in the machining center.

In the Grenzebach machining center, the castings are given the right finishing touches. There, the cast product becomes a high-quality component.

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In the case study, customers find out in which cases the casting manufacturing process is useful.

Optimum quality at the lowest possible costs – read our Case Study to discover whether casting parts or conventional machining of parts has the better cost-benefit ratio.

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Friction stir welding has many advantages.

Friction stir welding (FSW) creates an unprecedented welding quality. The metals are thereby stirred, not melted.

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Contact us any time!

Your contact person: Alfred Schlosser

Do you want to go into series production with a new component? Do you need expert feedback on an idea? We’re happy to help you!

Alfred Schlosser Grenzebach