Case Studies
Case Study Using Continuous Cast Iron
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Marini Manufacturing is excellence in action for all your production and prototype machining needs, and we're always up-to-date with the latest technology in the field. Take a look at some of our case studies below.
The Challenge
A large U.S. OEM was using gray iron castings on a high mix of low-volume pulleys. There were approximately 90 different part numbers involved, and these parts were being resourced back to the United States. Annual volumes ranged from 1 to 150 and part diameters from 3.00” to 22.00”
The organization did not want to invest a great deal in pattern repairs, modifications, or, in some cases, brand new patterns. They needed to find a substitute material that met their rigorous quality standards and a supplier they could count on for consistent on-time delivery.
The Solution
Marini Manufacturing chose a Highly Pearlitic Continuous Cast Gray Iron which conforms to ASTM A48, Class 40 Standards. A machining cell consisting of (2) Twin Spindle Live Tool VTLs, (1) VMC and a Static Balancer was set up to provide quick
changeover and turnaround on a high mix of parts.
“We are able to provide a quality product with a 75% reduced lead time.”
The Results
The OEM made the switch to continuous cast iron five years ago and continues to purchase the product. They are also looking at additional applications on a consistent basis, and we’ve been able to utilize it on prototype projects as well as provide initial production deliveries until cast tooling and production castings are available.
"Using continuous cast iron not only eliminated the need for costly repairs and new patterns, it eliminated porosity, foundry minimums and also reduced material lead times from an average of 8 weeks to 1 week."
"Using continuous cast iron not only eliminated the need for costly repairs and new patterns, it eliminated porosity, foundry minimums and also reduced material lead times from an average of 8 weeks to 1 week."
For more information about converting from casting to continuous cast iron, please contact Marini Manufacturing today!
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