The creation of your cast iron component

From idea to finished product

At ULDALL, we consider ourselves to be iron casting experts and we are happy to make our knowledge available right from the initial idea phase.

Below is a specific case where the customer transitioned from a welded to a cast structure in collaboration with us.

STARTING POINT

Welded structure

The customer is challenged by the low durability and strength of the welded construction of the component, as well as high costs. The high costs are due to laser cutting, twelve welds, and inconsistent strength, along with surface treatment. Therefore, the customer wants the component cast in iron.

THE IDEA IS CREATED

Design

The process begins with us collaborating with the customer to sketch and design the component based on their preferences. During the design phase, we advise our customers and ensure that the result meets both the technical, quality, and process-optimized requirements.

PRECISE DIMENSIONS AND SPECIFICATIONS

Sketching the component

The component is then sketched up in CAD and approved by the customer. Subsequently, the casting model itself is also drawn in CAD and imported into the CAM system, where it is processed.

SAND MOLD FOR CASTING

The sand mold is made

The casting model is used to make an imprint in chemically (furan) bound sand. The mold made of sand can withstand up to approx. 1,500 degrees and consists of a top and a bottom.

More about casting models

THE SAND CORE

The core forms the cavity

If there needs to be a cavity or a hidden geometry in the cast iron component, it requires a sand core. The sand for the core is mixed with binder and hardener and then injected into the core box with compressed air.

The cores are blackened to protect the cores from the high temperature and to provide a smooth internal surface for the cast items.

The core is placed in the bottom of the mould, after which the top is attached.

MOLTEN IRON IS POURED INTO THE MOLD

The component is cast

The mold is now ready for the approximately 1,500-degree molten iron to be poured into it. At ULDALL, this process is done manually and effectively using casting ladles.

Machining

The finished cast iron component

Once the iron has solidified, the component is released from the sand.

Subsequently, the component is cleaned and ground. If the customer desires, the component can be machined and surface-treated, making it ready for assembly for the customer's further use


The history of cast iron dates back thousands of years. Iron spearheads have been found dating as far back as 4,000 years before our era. Today, the use of cast iron is prevalent in many industries and sectors due to factors such as its durability and strength.