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Grey Iron Casting Manufacturers and Companies

IQS Directory provides an extensive list of grey iron casting manufacturers and suppliers. Utilize our website to review and source grey iron casting manufacturers with our easy-to-use features which allow you to locate grey iron casting companies that will design, engineer, and manufacture grey iron castings for your exact specifications. Our request for quote forms make it easy to connect with leading grey iron casting manufacturers. View company profiles, website links, locations, phone number, product videos, customer reviews, product specific news articles and other production information. We are a leading manufacturer directory who will connect you with the right manufacturers whether you are looking for sand castings, centrifugal castings, or grey iron casts.

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MES, Inc. produces & delivers a wide range of gray iron castings, serving construction, valve, pump & agriculture industries & many more. Our facility is ISO certified and our mission to provide you with the very best grey iron castings. If you would like to learn more information about our products and services then please give one of our representatives a call today!
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Imperial is a 46 year old company proud to produce quality grey iron castings for American Industry. Imperial specializes in many quality components, from 8 oz to 400 lbs, and employs experienced and talented professionals dedicated to their customers' satisfaction. Imperial serves a wide range of industries with top-quality, cost-effective solutions. Call Imperial today!
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U.S. Casting Company specializes in alloy castings and carbon steel castings. We are well known for our attention to detail and insistence on the highest quality in equipment and materials, as well as our commitment to testing and quality control.
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Willman stands for quality grey iron castings that you can count on for many years to come. As a leading manufacturer producing all types of precision components, weighing from ounces to 40,000 lbs, Willman can satisfy your demands for complex engineering solutions. Willman employs skilled workers & the most advanced equipment for economical production, giving you the quality assurance you want.
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The Simmons Group has been in business for over 50 years offering all types of castings and processes with weights from 1 ounce to 600 pounds plus. Whatever your requirements are for castings, Simmons has the resources to meet your needs in every casting method and material.
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Industry Information
View A Video on Grey Iron Castings - A Quick Introduction

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Grey iron castings are alloyed iron components manufactured by melting and molding molten metal at specific rates and temperatures so as to create parts and components of variable grades and qualities as needed for industrial applications. Also spelled gray iron, these castings have been used throughout history due to the abundance and low cost of iron.

A type of cast iron, the name of grey iron is derived not only from the basic elemental composition of the material, but also from the coloring of fractured surfaces of the metal. This method is commonly used to distinguish between iron alloys though the molecular structure is also very different. Even within the category of grey casting there are several different types, such as ductile castings and spheroidal graphite cast iron, based on molecular composition and internal structure. Even minor differences lead to considerable variation of the many desirable features of grey iron such as low melting point, resistance to deformation and wear, energy dissipation and thermal conductivity. As casting and machining can also alter these qualities, specific iron castings must be carefully compared to their intended use to ensure structural competence. Because so many variations exist, iron foundries often offer several different metallurgical and core processes to produce plain gray iron castings as well as ductile iron castings. One of the most popular operations is green sand casting, though die casting is also extremely popular within the industry. The selected casting method depends largely upon the desired size and characteristics needed for the finished part. Foundry professionals may provide additional insight into the most appropriate use of grey iron castings.

Making up 5% of the Earth's crust and 35% of its total mass, iron is the most copious element on the planet. Rarely found in pure form, however, iron oxides or iron ores must be mined and processed to produce grey iron. Metalworkers achieve this through the use of a special type of blast furnace known as a cupola or an electric induction furnace. Though several standardized grading systems are available, the general composition of grey cast iron is 95% iron by weight with an additional 2.1 to 4% being carbon and 1 to 3% silicon. Manganese and other impurities are also commonly found in or added to molten iron as needed for the diminishing or enhancement of specific properties. Sulfur, for example, is commonly introduced to the molten metal in order to increase hardness which is otherwise low in most cast iron components. Specific to grey cast iron is a high amount of silicone which is responsible for the production of graphite when the alloyed materials are heated. The deflection of this graphitic microstructure is what gives the metal its grey appearance. Though most often in flake form, ductile cast iron production slows down the growth of graphite and allows the carbon to separate as spheroidal graphite particles instead. Both the timing and temperature play important roles in the structural disposition of grey iron castings.

With desirable stock material readied, iron foundries use several different processes to produce grey iron castings. Virtually every technique requires the liquification of the grey iron which is then poured into a mold and cooled at precise rates before the completed part is ejected. Die casting employs reusable dies which contain an impression of the finished product. This method is popular when continuous cycle or fast production is needed. Centrifugal casting is used for cylindrical parts and components and works by rotating the mold at high speeds as the molten metal is introduced. This creates a fine grained outer surface with even dispersion. Sand molding is another commonly used process as it is low cost and easily accomplished. A two part mold cavity is formed using a sandy mixture, the composition of which can be any of four choices which include green sand, skin-dried, dry sand and no bake. The material chosen depends largely upon the accuracy needed and the desired surface finish which is often rough and may require finishing operations. As most mold and casting techniques leave the possibility for burrs and other undesirable artifacts, iron foundries often provide a number of secondary operations in order to provide more finished products. Additionally, processes such as annealing, machining, painting and galvanizing among others may also be had at several metallurgical work shops.

Though often confused with forges, only foundries provide the closed mold operations needed to produce quality grey iron castings for the many industries that employ them. Automotive, agricultural, machinery building, electronics, irrigation, ventilation, architecture, construction and transportation industries all utilize these molded parts in daily operations as they provide both strength and durability. As a building and construction component, grey iron castings provide protection against fires as they are non-flammable and thus preferred over wooden support structures. The graphite content of the parts also provides reliable and efficient energy dissipation making the parts suitable for applications in which the dampening of mechanical vibrations is required or desired such as crankshafts and engine blocks. Additional cast grey iron components commonly used include pipes, cases, dies and even decorative embellishments as the material is easily machined with accuracy and precision.
Grey Iron Casting
Grey Iron Casting
Grey Iron Casting
Grey Iron Casting - Fairfield Castings, LLC
Grey Iron Casting - Fairfield Castings, LLC
Grey Iron Casting - Calmego

Types of Grey Iron Castings

  • Alloy castings are a cast product that is composed of multiple metals. Almost all castings are alloys because it is difficult to mold a solitary metallic element.
  • Cast iron encompasses a large group of ferrous alloys containing between 1 and 3 % silicone and 2 to 4% carbon with a core of about 95% iron by weight. There are two predominant types of cast iron, those being grey iron and white iron.
  • Core processes involve the implementation of a block or barrier around which castings are made. The use of a core in this manner allows for the creation of internal cavities and reentrant angles in solid iron castings.
  • Ductile castings are molded iron components made with a particular group of cast iron alloys that are designed for improved flexibility as compared to traditional grey iron castings which tend to be brittle.
  • Ductile iron castings are very thin molded products cast out of iron or an iron alloy. A ductile casting has the ability to be stretched, hammered or drawn without breaking.
  • Gray iron castings are created by molding molten gray iron materials.
  • Gray iron, or cast iron, is an inexpensive and commonly used metal material.
  • Green sand casting uses disposable molds made of special sand based slurries to produce cast iron parts and components for a number of industrial uses. While some variations may actually appear green in color, the term is actually derived from wood working and references the wet state of the slurry during mold making. 
  • Grey casting is the production of molded products made of any of a particular group of iron alloys with notably high carbon and silicon content.
  • Grey iron is a type of metal often used in castings. In the past, grey iron was known as cast iron; however, cast iron is now made out of iron-carbon alloys that have a higher level of ductility.
  • Grey iron casting services are performed by foundries. They normally consist of one or more metals going through liquefaction, then pouring the molten material into a mold. After proper cooling, the mold is re-opened, and the casting is ejected.
  • Iron castings are any of variously designed products that are comprised of primarily iron. Iron is a very strong and plentiful material, making it a prime candidate for casting foundries.
  • Iron foundries are facilities which provide all of the services necessary to produce iron castings of various sizes and shapes.
  • Malleable iron castings are cast products that consist of mostly iron. Unlike a normal iron casting, one that is malleable has the ability to be shaped and bent without fracture.
  •  Spheroidal graphite cast iron is a group of iron alloys specially formulated to create molded products with heightened elasticity, tensile strength and durability.

Grey Iron Castings Terms

As-Cast Condition - Casting without later heat treatment.

Brinell Hardness Number (BHN) - A value given to a grey iron casting after undergoing a Brinell hardness test. Higher numbers indicate a harder material.

Brinell Hardness Test - A method used to measure how hard a material is. Typically for grey iron castings, a 3000kg metal ball is impressed on the surface of a flat grey iron piece; after removing the ball, the indentation in the metal is recorded and measured, determining a hardness value.

Chaplet - A small metal insert or spacer used in the molding process used to give support to the core.

Cope - The top half of a piece which has been forged or caste horizontally.

Deflection - The amount of bending or deformation that an iron casting endures due to an external load. Deflection is an important consideration for companies that plan on supporting a load with a grey iron casting.

Drag - The bottom half of a mold created horizontally.

Ductility - The ability of a grey iron casting to deform without being fractured. Iron castings have a considerable amount of ductility.

Ferrous - Any material that is made of or contains iron.

Foundry - A place where molten metal is poured into a mold, creating a metal casting.

Galling - A condition that results from excessive friction between metal surfaces. It creates surface deformation(s) and can result in temporary adhesion. Grey iron is renowned for its resistance to galling.

Hypereutectic Iron - Refers to an iron metal that is composed of more than 4.3 percent carbon.

Hypoeutectic Iron - Any iron alloy that is made up of 4.3 percent carbon or less.

Malleable - A property describing metals that can be pressed, hammered, formed, rolled, bent, etc.

Modulus of Elasticity - Measures the ration of stress to strain for an elastic material. Modulus of elasticity also describes stiffness of a material.

Permeability - The mold-metal property which allows passage of mold/core gasses during the pouring of molten metal.

Pilot Casting - Also known a sample casting in which a pattern produced by a production die is used to check the accuracy of the quality and dimensions of a potential order run casting.

Porosity - Holes formed in casting due to trapped gasses or chemical reactions between the molten metal and internal substances or objects such as chaplets.

Pounds per Square Inch (PSI) - The pressure a material applies on the walls of a closed enclosure. Atmospheric pressure at sea level is 14.7 psi.

Shrinkage - The decrease in the size of a material. Grey iron goes through little if any shrinkage when going through solidification.

Tensile Strength - The amount of stretching and bending that a material can undergo before breaking or tearing. The tensile strength for grey iron castings range from about 20,000 psi to 60,000 psi.

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