Manufacturing and workshop

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Manufacturing and workshop

CAST & CRAFT - CAST & CRAFT - CAST & CRAFT -
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Cast iron manufacturing is a metalworking process where molten iron—typically containing 2% to 4% carbon—is poured into molds to create various shapes. While ancient in origin, modern production utilizes advanced automation and induction furnaces to ensure precise metallurgical control.

The Manufacturing Process (Step-by-Step

Material Sourcing

Manufacturers combine pig iron with recycled steel, iron scrap, and alloys like silicon and manganese.

Melting

The mixture is heated in a furnace (cupola, electric induction, or electric arc) to temperatures exceeding 1,150°C (2,100°F) until it becomes liquid.

Pattern & Mold Making:

Sand Casting: The most common method. A pattern (often wood or metal) is pressed into a mixture of sand and binders (clay or resins) to create a hollow cavity.
Shell Molding: Uses reusable metal molds for smaller, higher-precision items.
Investment Casting: Uses wax patterns for highly intricate designs.
Pouring: Uses Molten iron is poured into the mold cavity. In cookware manufacturing, specialized machines often automate this to ensure even thickness.
Cooling & Shakeout: The metal solidifies within the mold. Once cooled, the mold is broken (in sand casting) or opened to release the “rough” casting.
Fettling & Finishing: Excess metal, sand, and surface scale are removed via shot blasting, grinding, or machining.
Surface Treatment: Depending on the end use, products may be painted, galvanized, or—in the case of cookware—pre-seasoned with vegetable oil or coated in enamel.

Common Types of Cast Iron

Grey Iron

The most common variety; contains graphite flakes, offering excellent machinability and damping capacity.

Ductile (SG) Iron

Created by adding magnesium, which forms spherical graphite nodules. This makes the iron flexible and resistant to impact, unlike brittle grey iron.

White Iron

Lacks graphite and is extremely hard and brittle; primarily used for wear-resistant parts like pump impellers.