Conversions Case Studies

Improve Classic Components with Conversion

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Waupaca Foundry Converts Steel Weldments to Iron Castings

Conversion from steel to cast iron benefits cost, quality, performance

OEMs and their Tier 1 suppliers are continually challenged with reducing supply chain risk and driving down cost without sacrificing quality or delivery. Converting a steel weldment to an iron casting is often a smart, cost-saving option for manufacturers.

Conversion to iron casting allows for more precise consistency and replication compared to steel weldments, leading to enhanced function, fit and performance. A steel fabrication converted to a single ductile iron or gray iron casting allows manufacturers to replace several weldment parts with a single cast iron part that is both stronger and lighter. It also simplifies assembly, can reduce or eliminate machining, and also cuts labor and logistics cost.

Additional benefits of converting welded parts to an iron casting:

Improve part durability and wear performance
Eliminate parts gap , warping and welding defects
Simplify assembly through scheduling and decreased labor time
Reduce parts inventory and cut administrative costs

Knowing when to switch to a casting is a collaborative effort. Waupaca Foundry works together with the OEM and machining supplier to determine possible areas for cost reduction and quality improvements through weldment conversion to iron casting. Foundry engineers can proactively evaluate the new iron components with MAGMA® iron flow and Arena-flow® core sand simulation models before tooling is built to confirm production part feasibility, quality and performance.

Click on the case studies below to discover how Waupaca Foundry has helped OEMs and their Tier 1 suppliers improve durability, increase performance and reduce costs by converting weldments into castings.

Conversions

Conversion to Ductile Iron Improves Durability and Eliminates Warranty Claims

To improve durability and wear of components assembled on commercial zero-turn mowers, Waupaca Foundry collaborated with both the machining supplier and the OEM. In short, multi-piece steel weldments were converted to single ductile iron castings.

#ductile #engineering #off-highway

Conversions

Conversion Transforms 10-Piece Weldment to Single Gray Iron Casting

A recent design project with the world’s largest agricultural equipment manufacturer shows what working together on casting designs can accomplish. Our customer needed a stronger, lighter alternative to the 66 pound, multi-part weldment used in their equipment. The old model was heavy and awkward to work with. It needed a makeover

#ductile #engineering #oem #off-highway

Conversions

First Cast-Iron Backhoe Bucket on the Market

Waupaca Foundry aided in the redesign and launch of the first-to-market cast iron bucket attachment for a compact utility tractor attachment OEM. After an innovative and collaborative design and problem-solving process, the resulting backhoe bucket and teeth are more durable, cost-effective, and made in the United States.

Recent Iron Casting Blogs