Jobbing casting

This range of services from Keulahütte includes sophisticated industrial castings for use in general mechanical engineering, the construction of lifting equipment and vehicle construction. While cast parts of 5 to 200 kg are produced in the machine moulding shop (moulding box dimensions 1250 mm x 1000 mm x 350/350 mm), manufacturing options for cast parts weighing up to 4.5 t are available through the hand-moulding shop. Two large model warehouses with a total area of 3400 m² and fire monitoring provide optimal storage space for modelling equipment, both for the in-house product range and for industrial castings.

The following ductile cast iron and grey cast iron grades are cast:

Cast iron with spheroidal graphite

Designation in accordance with DIN EN 1563			EN-GJS-350-22-LT	EN-GJS-400-18-LT	EN-GJS-400-15	EN-GJS-450-10	EN-GJS-500-7	EN-GJS-600-3	EN-GJS-700-2	EN-GJS-800-2	EN-GJS-450-18	EN-GJS-500-14	EN-GJS-600-10
Reference analysis	C		3.50 - 3.70	3.50 - 3.70	3.50 - 3.70	3.20 - 3.50	3.50 - 3.70	3.50 - 3.70	3.50 - 3.70	3.50 - 3.70	3.20 - 3.50	3.00 - 3.30	2.80 - 3.10
for medium wall thicknesses	Si		1.80 - 2.00	2.30 - 2.60	2.30 - 2.60	2.80 - 3.20	2.30 - 2.60	2.30 - 2.60	2.30 - 2.60	2.30 - 2.60	2.80 - 3.20	3.40 - 3.80	3.90 - 4.30
	Mn		max. 0.2	max. 0.25	max. 0.25	max. 0.40	max. 0.40	max. 0.40	max. 0.40	max. 0.40	max. 0.50	max. 0.50	max. 0.50
	Mo		-	-	-	-	-	-	-	-	-	-	-
	Ni		-	-	-	-	-	-	-	-	-	-	-
Microstructure			Ferrite 100:1	Ferrite 100:1	Ferrite and pearlite 100:1	Ferrite and pearlite 100:1	Ferrite and pearlite 100:1	Pearlite and Ferrite 100:1	Pearlite and Ferrite 100:1	Pearlite 100:1	Ferrite 100:1 (Solid-solution hardening)	Ferrite 100:1 (Solid-solution hardening)	Ferrite 100:1 (Solid-solution hardening)
Mechanical properties ¹⁾
Tensile strength	R_m	MPa	350	400	400	450	500	600	700	800	450	500	600
0.2 Yield strength	R_p0.2	MPa	220	240	250	310	320	370	420	480	350	400	470
Elongation at fracture	A₅	%	22	18	15	10	7	3	2	2	18	14	10
Elastic modulus	E	GPa	169	169	169	169	169	174	176	176	170	170	170
Notched bar impact work²⁾	at +23°C (RT)	Joule	17	14	-	-	-	-	-	-	8	3	-
	at -20°C (LT)	Joule	-	12	-	-	-	-	-	-	4	3	-
	at -40°C (LT)	Joule	12	-	-	-	-	-	-	-	3	2	-
Brinell hardness	HBW		< 160	130 - 175	135 - 180	160 - 210	170 - 230	190 - 270	225 - 305	245 - 335	170 - 200	185 - 215	200 - 230
Endurance limit³⁾		MPa	180	195	-	210	224	248	280	304	210	225	275
Fatigue limit⁴⁾		MPa	114	122	-	128	134	149	168	182	130	140	165
Technological properties
Usage temperature⁵⁾			< 500	< 500	< 500	< 500	< 500	< 500	< 500	< 500	< 500	< 500	< 500
Machinability			very well	very well	very well	well	well	well	medium	medium	well	well	well
Wear resistance			low	low	low	low	well	well	very well	very well	low	low	low
Induction or flame-hardening capacity			low	low	low	low	low	well	very well	very well	low	low	low
Nitriding capacity			well	well	well	well	well	well	very well	very well	well	well	well
Weldability			Only weldable using special electrodes				Only weldable using special electrodes				Only weldable using special electrodes
Physical properties
Density	ρ	kg/dm³	7.10	7.10	7.20	7.10	7.10	7.20	7.20	7.20	7.1	7.0	7.0
Thermal conductivity	λ at 300°C	W/(K*m)	36.2	36.2	36.2	36.2	35.2	35.2	31.1	31.1	-	-	-
Thermal expansion coefficient	α to 400°C	10^-6/K	12.5	12.5	12.5	12.5	12.5	12.5	12.5	12.5	-	-	-
			Special materials or grades not listed available on request

¹⁾ The mechanical properties of cast iron with spheroidal graphite in integrally cast Y-shaped test specimens (minimum values)
²⁾ Mean value of three ISO-V test specimens (DIN 50115)
³⁾ Wöhler rotating bending fatigue test, unnotched test specimen
⁴⁾ Wöhler rotating bending fatigue test, notched test specimen
⁵⁾ Literature values

Cast iron with lamellar graphite

Designation in accordance with DIN EN 1561				EN-GJL-150	EN-GJL-200	EN-GJL-250	EN-GJL-300
Reference analysis	C			3.40 -3.60	3.20 - 3.40	2.90 - 3.10	2.90 - 3.10
for medium wall thicknesses	Si			2.30 - 2.60	2.00 - 2.40	1.80 - 2.10	1.60 - 1.90
	Mn			0.60 - 0.90	0.70 - 1.00	0.80 - 1.10	0.80 - 1.10
Microstructure				Pearlite, coarse lamellar 100:1	Pearlite, coarse lamellar 100:1	Pearlite, fine lamellar 100:1	Pearlite, fine lamellar 100:1
Mechanical properties ¹⁾
Tensile strength	R_m	MPa		150 - 250	200 -300	250 - 350	300 - 400
- Dependent on wall thickness	R_m	MPa	2.5 - 50mm	150	200	-	-
			5 - 50mm	-	-	250	-
			10 - 50mm	-	-	-	300
			50 - 100mm	130	180	220	260
			100 - 200mm	110	160	200	240
Yield strength	R_p0.1	MPa		98 - 165	130 - 195	165 - 228	195 - 260
Elongation at fracture	A	%		0.8 - 0.3	0.8 - 0.3	0.8 - 0.3	0.8 - 0.3
Elastic modulus	E	GPa		78 - 103	88 - 113	103 - 118	108 -137
Bending fatigue strength		MPa		0.46 x R_m	0.46 x R_m	0.46 x R_m	0.46 x R_m
Compression-tension fatigue strength		MPa		0.34 x R_m	0.34 x R_m	0.34 x R_m	0.34 x R_m
Hardness/material designation				EN-GJL-HB175	EN-GJL-HB195	EN-GJL-HB215	EN-GJL-HB235
-Dependent on wall thickness	HBW		2.5 - 50mm	115 - 175	-	-	-
			5 -50mm	-	135 - 195	155 - 215	-
			10 - 50mm	-	-	-	175 - 235
			50 - 100mm	105 - 165	125 -185	145 - 205	160 - 220

Technological properties
Machinability				very well	very well	very well	very well
Wear resistance				medium	well	very well	very well
Induction or flame-hardening capacity				bad	low	well	very well
Nitriding capacity				well	well	well	very well
Damping				very well	very well	very well	very well
Weldability				Only weldable using special electrodes
Physical properties
Density	ρ	kg/dm³		7.10	7.15	7.20	7.25
Thermal conductivity	λ at 300°C	W/(K*m)		50.0	48.0	46.5	45.0
Thermal expansion coefficient	α to 400°C	10^-6/K		13.0	13.0	13.0	13.0
				Special materials or grades not listed available on request

¹⁾ The mechanical properties in integrally cast test specimens with a diameter of 30 mm (minimum values)

The quality assurance or quality certification options are divided into:

Ultrasonic testing (US) DIN 16280-3
Crazing and surface testing
Magnetic particle testing (MP) DIN EN 1369
Dye penetrant testing (PT) DIN EN 1371
Visual inspection (VP)
Radiographic test in cooperation with DIN EN 12681

Using solidification simulations, hotspots are already detected as focal points for feeding during the preparation phase so that time-consuming testing to find a suitable casting and feed technology can be reduced to a minimum.

Services

Our comprehensive services are fully geared towards efficient cooperation with customers and market partners. We a committed to an integrated and process-oriented working principle,

in which we place great emphasis on product quality and customer satisfaction.