How Steel Castings are Made

Steel castings are produced from recycled scrap steel melted in an Electric Arc Furnace (EAF) or Induction Furnace.

Close up of worker next to a furnace
CAST CONNEX steel castings are made from ASTM and EN grades fit for structural purpose and chosen to meet project requirements. These cast steel grades are low alloy, weldable, ductile, and exhibit high strength and toughness.

DESIGN

CAST CONNEX designs are responsive to the structural and architectural needs of the project as well as to the constraints of the casting manufacturing process

Patternmaking

A casting design first moves from the digital to the physical realm during patternmaking.

3D digital models developed during the design process are used to create patterns – a replica of the part to be cast – which are used in the mold making process. Patterns are typically made from wood, resin, or aluminum and are produced via CNC-manufacturing. Additive manufacturing (3D printing) can also be used in patternmaking.

Molding

Patterns are used multiple times to generate sand molds for each unique casting geometry

Pouring

The Transition From Molten
to Cast Steel 

Wide shot of how castings are made
Prior to pouring, the chemical composition of the molten metal is determined via spectrochemical analysis.
With pouring complete, the molten metal begins to solidify or freeze. The solidification time of a casting is a function of volume and surface area. Because removal of a casting from its mold while it is still too hot may damage or distort the part, castings are left in their molds to cool for some time after they have solidified. Given the wide range of components that CAST CONNEX supplies, our parts remain in their molds anywhere from a few hours to an entire week.

Heat Treatment

Steel castings exhibit isotropic mechanical properties

which makes them ideal for use in applications wherein the part will be subjected to complex stress states, like the multiaxial connection node shown here.

In steel casting manufacturing, heat treatment is employed in conjunction
with alloying to achieve the desired mechanical properties in the casting. Heat treatment also relieves residual stresses that may have developed during solidification or casting production welding.
Large Close Up of Heat Treatment of a Massive Cast
Heat treatment of the 35,000lb Queen Richmond Center West node
testing

Ensuring Steel Castings Meet Performance Requirements

Tensile and Charpy (CVN) impact testing is typically conducted on cast steel material that is cast from the same heat as, and heat treated along with, the component that it is intended to represent. This may take the form of test blocks, alternatively, coupons can be cut directly from castings (or the parts of castings) that have been set aside for destructive testing.

Yield strength, tensile strength, elongation, reduction of area, and CVN toughness are measured for each heat and reported on Certified Material Test Reports (CMTRs) provided for every CAST CONNEX product.

Wide Shot of How Castings are Made
Steel castings are generally more ductile than their rolled steel counterparts.
0/0

Non-Destructive Examination

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Non-Destructive Examination is essential to casting manufacturing. The following are some of the NDE methods utilized in the production of CAST CONNEX products.

Radiographic Testing

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Image of Radigraphic Testing

Radiographic Testing (RT) is employed to identify subsurface defects in cast steel products. In RT, film media and a radioactive source are positioned on opposing sides of a casting’s wall or feature, with the component and film medium beyond the component then exposed to ionizing radiation for an amount of time that is proportional to the part’s thickness. Films are subsequently reviewed and compared to reference radiographs to provide insight as to the internal soundness of the casting.

Ultrasonic Testing

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Ultrasonic Testing (UT) is employed to identify subsurface defects in cast steel products. It can also be used to measure the wall thickness of a casting. In UT, a transducer is used to impart high-frequency sound waves to the cast steel product and to measure the waves that are reflected back to the transducer. The transit time, amplitude, and shape of the reflected waves are monitored during inspection and provide the inspector insight as to the internal soundness of the casting.

Magnetic Particle Testing (MT)

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Magnetic Particle Testing (MT) is used to identify surface and near surface defects in cast steel products. During MT, the steel casting is magnetized by passing a high-amperage, low-voltage current through the part and fine magnetic particles (often florescent) suspended in a carrier fluid are applied to the surface of the part. Discontinuities near or at the surface of the casting disrupt the magnetic field and result in a flux, which in turn causes the particles in the medium to concentrate in those areas, enabling visual identification of the flaw. Liquid Penetrant Testing can also be employed for the identification of surface defects.

Visual Examination

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Close up of steel casting samples

Visual Examination is used extensively in casting manufacturing. Visuotactile reference comparator plates assist in the assessment of the surface quality and texture of as-cast surfaces on steel castings. Surface finish is a feature of castings that can be specified by the project team to fit with aesthetic goals of the project. CAST CONNEX Standardized Products are supplied with surface finish compatible with high quality architecturally exposed structural steel (AESS)

Visual Examination

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

CAST CONNEX products are manufactured to tolerances that are an order of magnitude tighter than those achievable via fabrication, offering unmatched accuracy and precision in geometrically complex connections.

Dimensional Inspection (CMM)

Every CAST CONNEX component is subject to a battery of Non-Destructive Examination.

Coordinate measuring machines (CMM) are utilized throughout the casting manufacturing process. CMM is used to dimensionally inspect the as-cast geometry of the part, to assist in balancing the part prior to CNC machining, and to measure and document the finished product prior to shipping.

Contact Us

Want to leverage steel castings in your work?

Whether your interest in cast steel components is general or project-specific, we look forward to speaking with you.