Page 1
CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Hydraulic Motor RearHousing
APPLICATION Allows Changing ofHydraulic MotorDisplacement
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN Was a Three PieceAssembly of SteelPlate That Required aConsiderable Amount ofMachining
COST SAVINGS Component CostReduced 44%
DESIGN Improved Wear andADVANTAGES Machining Characteristics;
Cost Savings ProvidedCost Competitiveness
SIZE & WEIGHT Approx. 100 lb. Casting
COMPANY Rineer HydraulicsSan Antonio, TX
FOUNDRY Alamo Iron WorksSan Antonio, TX
CASTING Lift Arm
APPLICATION Raise & Lower MotorGrader Blade
SPECIFICATION ASTM A-536 (65-45-12)
REDESIGN From Steel Casting
COST SAVINGS Part Cost Reduced 47%
DESIGN Lower ManufacturingADVANTAGES Costs
SIZE & WEIGHT Unknown
COMPANY Caterpillar Inc.Decatur, IL
FOUNDRY Unknown
CASTING Forward-Reverse Gear
APPLICATION Power TransmissionPart
SPECIFICATION ASTM A-536 (100-70-03)
REDESIGN From Steel Forging,Steel Stamping, andShaft
COST SAVINGS $402,000 AnnualSavings
DESIGN High Fatigue Strength;ADVANTAGES Good Response to Heat
Treatment; ReducedNumber of Parts;Reduced Operationsfrom 18 to 9
SIZE & WEIGHT 6" Diameter Gear
COMPANY Unknown
FOUNDRY Dotson CompanyMankato, MN
CASTING Syphon Elbow
APPLICATION Condensate RemovalFrom Paper Dryer
SPECIFICATION ASTM A-536 (60-40-18)Investment Cast
REDESIGN From Bronze
COST SAVINGS Cost Reduced 10% PerPart
DESIGN Increased Strength;ADVANTAGES Reduced Machining Time
SIZE & WEIGHT 5 oz. to 2 lbs. 11 oz.
COMPANY The Johnson Corp.Three Rivers, MI
FOUNDRY Unknown
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP20 21
Page 2
CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Gland
APPLICATION Hydraulic Cylinder
SPECIFICATION ASTM A-536 (65-45-12)
REDESIGN From Gray Iron Casting
COST SAVINGS Part Cost Reduced66%; ReducedOperations from 10 to 3
DESIGN Stronger; Quality isADVANTAGES Improved; Better
Machinability; MoreEconomical
SIZE & WEIGHT Variable
COMPANY Seitz Mfg. Co. Inc.Milwaukee, WI
FOUNDRY Unknown
CASTING Steering Column Support
APPLICATION Support Steering Column;Absorb Air Bag and CrashLoads
SPECIFICATION SAE J-434C (D4512)
REDESIGN From Steel Weldments andMultiple Stampings
COST SAVINGS Unknown
DESIGN Stronger; ImprovedADVANTAGES Performance Safety
Related Part
SIZE & WEIGHT 15" x 4"
COMPANY Wagner CastingDecatur, IL
FOUNDRY Same as Above
CASTING Clutch Cup
APPLICATION Farm Tractor PowerTake-Off
SPECIFICATION ASTM A-536(100-70-03)
REDESIGN From Steel Forging
COST SAVINGS Part Cost Reduced 32%;$112,000 Annual Savings
DESIGN Substantial Cost SavingsADVANTAGES While Still Retaining
Tensile and YieldStrengths
SIZE & WEIGHT 6" x 5"
COMPANY International HarvesterRock Island, IL
FOUNDRY International HarvesterMemphis, TN
CASTING Air Suspension Hanger
APPLICATION Converter Dolly
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced 53%;$58,000 Annual Savings
DESIGN Increased Service LifeADVANTAGES 10-15 Times; Decreased
Assembly Time 83%;Eliminated Welding
SIZE & WEIGHT Approx. 12"
COMPANY Todco Div. Overhead DoorHaywood, CA
FOUNDRY Atlas Foundry & Mfg.Richmond, CA
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP22 23
Page 3
CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Plug Valves
APPLICATION Fluid Handling
SPECIFICATION ASTM A-536 (60-40-18)
REDESIGN From Stainless Steel,Titanium, Monel
COST SAVINGS Part Cost Reduced66%; $3,000,000 Annual Savings
DESIGN Provided CloseADVANTAGES Dimensional Tolerances;
Facilitated Installation ofPlastic Liner
SIZE & WEIGHT Various
COMPANY Continental Mfg.Cincinnati, OH
FOUNDRY Lynchburg FoundryLynchburg, VA
CASTING Tool Storage Index
APPLICATION N/C Machining Center
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced 80%
DESIGN Reduced ProductionADVANTAGES Operations from 2,115
to 24; Improved Appearance
SIZE & WEIGHT Unknown
COMPANY National Automatic ToolRichmond, IN
FOUNDRY Unknown
CASTING Rear Engine Mount
APPLICATION Engine Support andTorque ReactionMember
SPECIFICATION SAE J-434C (D4512)
REDESIGN From Steel Stamping
COST SAVINGS Lowered Tooling & PerPiece Costs
DESIGN Stiffer Design; 38%ADVANTAGES Weight Reduction; More
Compact Product GivesLess PackagingInterference Problems
SIZE & WEIGHT 5" x 4"
COMPANY Ford Motor Co.
FOUNDRY Wagner CastingDecatur, IL
CASTING Crankcase
APPLICATION Air Compressor
SPECIFICATION ASTM A-536 (60-40-18)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced82%; $100,000 AnnualSavings
DESIGN Better Resistance toADVANTAGES Shock Damage;
Improved SoundDampening
SIZE & WEIGHT 48" x 36" x 72"
COMPANY Worthington Corp.Harrison, NJ
FOUNDRY Unknown
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP24 25
Page 4
DUCTILE IRON SOCIETYFOUNDRY MEMBERS
Aimco Foundry Corporation3300 N. SylvaniaFt. Worth, TX 76111817-838-2301 • Fax 817-831-3609
Alabama Ductile Casting Company123 St. Joseph StreetBrewton, AL 36426205-867-5481 • Fax 205-867-8638
American Cast Iron Pipe Company1501 31st Avenue NorthBirmingham, AL 35202-2727205-325-7954 • Fax 205-325-8921
Baker Manufacturing Company133 Enterprise StreetEvansville, Wi 53536608-882-5100 • Fax 608-882-6776
Bay Engineered Casting Company1900 Enterprise DriveDePere, WI 54115414-336-5781 • Fax 414-336-3567
Berlin Foundry Corporation242 South Pearl StreetBerlin, WI 54923414-361-2220 • Fax 414-361-4017
Briggs & Stratton CorporationCastings Division1706 S. 68th StreetWest Allis, WI 53214414-259-5333 • Fax 414-259-5959
Buck Company, Inc.897 Lancaster PikeQuarryville, PA 17566717-284-4114 • Fax 717-284-3737
CifnusaBlvd. Isidro Lopez 1255Saltillo, Coahuila 25000Mexico52-84-158316Fax 52-84-158496
CMI International, Inc.30333 Southfield Rd.Southfield, MI 48076313-642-9450 • Fax 313-642-4955
CMI Tech Center, Inc.1600 West Eight Mile RoadFerndale, MI 48220313-399-9600 • Fax 313-399-3512
CMI-Cast Parts, Inc.A CMI International Co.1500 Fourth AvenueCadillac, MI 49601616-779-9600 • Fax 616-779-9640
CT-South, Inc.Route 45 SouthMarion, AL 36756205-683-6101 • Fax 205-683-8365
CWC CastingsA Divison of Textron, Inc.1085 W. Sherman Blvd.Muskegon, MI 49441-3588616-733-1331 • Fax 616-739-2649
Cast-Fab Technologies, Inc.3040 Forrer StreetCincinnati, OH 45209513-758-1000 • Fax 513-758-1002
Chrysler Corporation12800 Oakland AvenueHighland Park, MI 48288-1118313-956-3750 • Fax 313-252-6310
Citation Corporation2 Office Park CircleBirmingham, AL 35243205-871-5731
Columbus Foundries, Inc.An Intermet Corporation Co.1600 Northside Ind. Blvd.Columbus, GA 31995404-323-5221 • Fax 404-324-1138
Cooper IndustriesIndustrial Machinery Division700 MainLa Grange, MO 63448314-655-2291 • Fax 314-655-4361
Donsco, Inc.North Front StreetWrightsville, PA 17368717-252-1561 • Fax 717-252-4530
Dotson Company, Inc.200 W. Rock St.Mankato, MN 56001507-345-5018 • Fax 507-345-1270
Ellwood Engineered Castings7158 Masury Rd., S.E.Hubbard, OH 44425216-534-8668 • Fax 216-534-0069
Enterprise Foundry, Inc.South AvenueLewiston, ME 04241-1564207-782-5511 • Fax 207-783-0897
Ford Motor CompanyBrook Park5600 Henry Ford Blvd.Brook Park, OH 44142216-676-7113
Ford Motor CompanyCanadaWindsor, Ontario N9A 2S5Canada519-257-4502
Ford Motor CompanyDearborn3001 Miller RoadDearborn, MI 48120313-322-4943 • Fax 313-845-1716
Foundry Service Company530 E. Main StreetBiscoe, NC 27209919-428-2111 • Fax 919-428-4986
Francis & Nygren Foundry Company6911 W. 59th StreetChicago, IL 60638773-586-7100 • Fax 773-586-7117
Frazier & Frazier IndustriesSouth 1st StreetCoolidge, TX 76635817-786-2293 • Fax 817-786-2284
G.M. Powertrain DivisionMassena, NY315-764-2321
G.M. of Canada Foundry570 Glendale AvenueSt. Catharines, Ontario L2R 7B3Canada416-641-6550 • Fax 416-641-6361
General Casting CompanyCincinnati Division1740 Powers StreetCincinnati, OH 45223513-541-6121 • Fax 513-541-0628
General Casting CompanyDelaware Division550 S. Liberty RoadDelaware, OH 43015614-363-1941 • Fax 614-363-0103
General Casting CompanyDomestic DivisonN. Queen StreetShippensburg, PA 17257717-532-6615 • Fax 717-532-3743
General Casting CompanyEdwin Poulton Foundry1071 Goodale Blvd.Columbus, OH 43212614-224-3750 • Fax 614-224-5863
General Casting CompanyToledo Street Division148 Toledo StreetDelaware, OH 43015614-363-1941 • Fax 614-363-0103
Glidewell SpecialtiesFoundry Co.600 Foundry RoadCalera, AL 35040205-668-1881 • Fax 205-668-1972
Globe Iron Foundry, Inc.5649 E. Randolph StreetLos Angeles, CA 90040213-723-8983 • Fax 213-888-9664
Grede Foundries, Inc.9898 W. Bluemound RoadMilwaukee, WI 53226414-257-3600 • Fax 414-257-4102
Grede Foundries, Inc.Liberty Foundry6432 W. State StreetWauwatosa, WI 53213414-771-6700 • Fax 414-771-1247
Grede Foundries, Inc.New Castle Foundry2700 E. Plum StreetNew Castle, IN 47362317-521-8000 Fax 317-521-8000 ext. 224
Grede Foundries, Inc.Reedsburg Foundry700 Ash StreetReedsburg, WI 53959608-524-6424 • Fax 608-524-9501
Grede Foundries, Inc.Wichita Foundry805 E. BostonWichita, KS 67211316-262-7204Fax 316-262-7204 ext. 346
Gregg Industries, Inc.10460 HicksonEl Monte, CA 91734818-575-7664 • Fax 818-401-0971
Grinnell Corporation1411 Lancaster AvenueColumbia, PA 17512717-684-4400 • Fax 717-684-2131
Harrison Steel Castings Company900 Mound StreetAttica, IN 47918317-762-2481 • Fax 317-762-2487
Harvard Industries, Inc.Albion Plant601 North Albion StreetAlbion, MI 49224517-629-2141 • Fax ext. 212
Harvard Industries, Inc.Jackson Operation1999 Wildwood AvenueJackson, MI 49202517-782-9421 • Fax 517-782-4478
Harvard Industries, Inc.Tiffin Division745 S. Seneca County Road 13Tiffin, OH 44883419-448-9310 • Fax 419-447-3357
Hodge Foundry, Inc.42 Leech RoadGreenville, PA 16125412-588-4100 • Fax 412-588-0152
Intermet Corporation 2859 Paces Ferry RoadSuite 1600Atlanta, GA 30339404-431-6000
John Deere Foundry Waterloo2000 Westfield AvenueWaterloo, IA 50704-2000319-292-5600 • Fax 319-292-5027
John Deere Technical Center3300 River DriveMoline, IL 61265309-765-3854
Kingsport Foundry & Mfg. Corp.145 Unicoi StreetKingsport, TN 37662615-246-8150 • Fax 615-246-2077
Lufkin Industries601 South RaguetLufkin, TX 75902-0849409-637-5311 • Fax 409-637-5429
Lynchburg Foundry Co.Archer Creek PlantLynchburg, VA 24505804-528-8200
Lynchburg Foundry CompanyAn Intermet Corporation Co.620 Court StreetLynchburg, VA 24505804-528-8200 • Fax 804-528-8301
Lynchburg Foundry CompanyLower Basin PlantLynchburg, VA 24505804-528-8200
Lynchburg Foundry CompanyRadford PlantRadford, VA 24141703-731-0400
Neenah Foundry Company2121 Brooks AvenueNeenah, WI 54957414-725-7000 • Fax 414-729-3652
Noblesville Casting, Inc.1600 South 8th StreetNoblesville, IN 46060317-773-3313 • Fax 317-776-0787
Northern Castings CoporationAn Intermet Corporation Co.555 West 25th StreetHibbing, MN 55746218-263-8871 • Fax 218-263-5039
Ohio Cast Products, Inc.2408 13th Street N.E.Canton, OH 44705216-456-4784 • Fax 216-456-2247
Pier Foundry and Pattern Shop, Inc.51 State StreetSt. Paul, MN 55107612-222-4461 • Fax 612-222-4185
Precision Metalsmiths, Inc.1081 E. 200th StreetCleveland, OH 44117216-481-8900 • Fax 216-481-8903
Precision Metalsmiths, Inc.Midwest Division1149 N. Margaret StreetMarkesan, WI 53946414-398-2361 • Fax 414-398-3644
Quality Castings Company1200 N. Main StreetOrrville, OH 44667216-682-6010 • Fax 216-683-3153
Richmond Casting Company, Inc.1775 Rich RoadRichmond, IN 47374317-935-4090 • Fax 317-935-2168
St. Marys Foundry, Inc.405-409 E. South StreetSt. Marys, OH 45885419-394-3346 • Fax 419-394-8269
Standard Automotive Parts660-666 Nims St.Muskegon, MI 49442616-722-6646 • Fax 616-726-5100
Technocast, Inc.1100 N. Main StreetOrrville, OH 44667216-684-2010 • Fax 216-683-0321
Teledyne Casting Service300 Philadelphia StreetLaPorte, IN 46350219-362-1000 • Fax 219-324-5414
Texas Foundries, Inc.1611 North Raguet (75901)Lufkin, TX 75903-3718409-632-4451 • Fax 409-639-6126
Tyler Pipe IndustriesTyler, TX 75710903-882-5511Fax 1-800-24-TYLER
Valmet Sandy Hill, Inc.27 Allen StreetHudson Falls, NY 12839-0803518-747-3381 • Fax 518-747-1541
Victaulic Company of America4901 Kesslersville RoadEaston, PA 18042215-559-3300 • Fax 215-250-8817
Wagner Castings CompanyDecatur Division825 North LowberDecatur, IL 62525217-428-7791 • Fax 217-425-6662
Ward Manufacturing, Inc.115 Gulick StreetBlossburg, PA 16912-0009717-638-2131 • Fax 717-638-3410
Waupaca Foundry, Inc.311 Tower RoadWaupaca, WI 54981715-258-6611 • Fax 715-258-9268
Wells Manufacturing CompanyCastwell Division7800 North Austin AvenueSkokie, IL 60077-4342847-966-5050 • Fax 847-966-8876
Wells Manufacturing CompanyDura-Bar Division1800 West Lake Shore Dr.Woodstock, IL 60098-7426815-338-7800 • Fax 815-338-8845
Western Foundry Company Limited454 Industrial RoadWingham, Ontario N0G 2W0Canada519-357-3450 • Fax 519-357-2486
Western Foundry Company LimitedBrantford DivisionPowerline Road WestBrantford, Ontario N3T 5W5Canada519-759-0452 • Fax 519-759-8535
Wheland Foundry–Division of NorthAmerican Royalties, Inc.2800 S. Broad StreetChattanooga, TN 37402615-265-3181 • Fax 615-756-3179
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP26 27