Reverse Engineered Wear Castings
From a worn part with no drawing to a repeatable casting
What This Casting Does And Why It Matters
Most of the parts customers cannot buy any more have one thing in common: there is no drawing, only the worn component still bolted to the machine. That is a workable starting point here. We 3D scan the part — on your site if it cannot be shipped — build the pattern in our own pattern shop, run Casting Process Simulation System before moulding, and pour it in the wear alloy the duty calls for.
Technical Features
- 3D scanner and Solidworks/CAD modelling in-house
- Casting Process Simulation System run before the mould is made
- Austenitic manganese, high chromium white iron and alloy steels available
- Machined in-house on vertical lathes to Ø3.4 m and gantry mills
- Single castings poured up to 10 tonnes
What You Get That You Would Not Get Elsewhere
No drawing required — the worn part is enough to start from
On-site 3D scanning where the component cannot be removed or shipped
In-house pattern shop, so tooling is not subcontracted or delayed
CPSS simulation before moulding to predict shrinkage and inclusions
The Failures This Part Is Cast To Prevent
- A critical part whose manufacturer no longer supports the machine
- No drawings anywhere — only the component itself
- Suppliers who quote catalogue parts but decline bespoke work
- Pattern costs hard to justify against a small annual quantity
Who It Is For
- Plants running older or modified equipment
- Mining operations with engineered wear components
- Equipment builders needing a contract wear-parts foundry
- Maintenance teams facing an obsolete part
Application Scenarios
- Wear components for obsolete crushing plant
- Prototype parts before a production run
- Low-volume castings that general foundries decline
- Modified equipment with no original documentation
Technical Data For Reverse Engineered Wear Castings
Every figure here comes from our published foundry capability. Where a value depends on your machine it is confirmed at quotation rather than guessed.
| Specification | Detail |
|---|---|
| Service | Reverse engineering and custom casting |
| Input accepted | Worn sample, drawing, or on-site 3D scan |
| Design tools | Solidworks, CAD, 3D scanner, CPSS |
| Materials | Austenitic manganese steels, high chromium white irons Cr15/Cr25/Cr30, alloy steels |
| Max single casting weight | 10 t |
| Max machining diameter | Ø3.4 m |
| Melting | 5 t intermediate frequency furnace × 2, bottom-poured |
| Inspection | Chemical analysis and dimensional report standard |
| Packing | Steel pallet |
How This Casting Is Made
Pattern Making
Once drawings are confirmed, pattern making starts immediately in our own pattern shop. Thousands of finished patterns are already on the shelf, so repeat parts skip this step entirely.
Sandbox Making
Casting Process Simulation System (CPSS) is run before the moulds are made. The cavity is kept as solid and as clean as possible so that inclusions have nowhere to start.
Melting And Pouring
Charge materials are bought to a high standard and temperature is controlled through the whole pour to achieve a fine grain structure. Samples are taken to verify the analysis and adjusted if needed, then kept for at least three years for traceability.
Sandbox Opening
Also called casting cleaning. After initial cooling the box is opened, risers and runners are removed and the casting is cleaned. Cooling time is set by casting size, not by the clock.
Heat Treatment
Heating temperature is strictly controlled and castings are spaced in the furnace so they heat uniformly and meet the water fully. Quenching begins within 30 seconds of withdrawal from the oven.
Machining
After rectifying and polishing, castings are machined strictly to drawing for correct fitment. QC then carries out dimensional inspection and issues the dimensional inspection report.
Inspection
Our own physical and chemical laboratory covers spectrometry, hardness, microstructure, dye penetrant and dimensional inspection on site rather than at a third party.
Packing And Delivery
Finished parts are packed on steel pallets for forklift handling, to international standards for road, rail, sea and air transport.
Inspection Supplied With This Part
Chemical analysis and a dimensional inspection report are standard on every order. The remaining procedures are carried out in our own physical and chemical laboratory when specified at order stage.
| Procedure | When |
|---|---|
| Chemical Analysis | standard on every heat |
| Dimensional Inspection Report | standard on every order |
| Hardness Testing | if specified |
| Tensile Testing | if specified |
| Microstructure Analysis | if specified |
| Magnetic Particle Testing | if specified |
| Dye Penetrant Testing | if specified |
| Ultrasonic Testing | if specified |
Laboratory Equipment
- German-made OBLF direct-reading spectrometer
- Hardness testing equipment
- Metallurgical microscope
- Dye penetrant inspection equipment
- Dimensional inspection equipment
How This Part Compares With The Alternatives
| Compared With | What Changes |
|---|---|
| A general jobbing foundry | Wear alloys, heat treatment and the machining to finish them are all in one works here, rather than spread across three suppliers. |
| Fabricating a replacement | A fabricated part rarely matches the wear behaviour of the casting it replaces, especially in manganese duties. |
| Waiting for OEM support | Where the machine is no longer supported there is nothing to wait for. A scan and a pattern is the route back into production. |
If Your Part Is Not Standard
With our own pattern shop, a 3D scanner and Casting Process Simulation System, we work from your drawing, your worn sample, or a scan taken on your site. Material grade, profile and machining are all specified against your machine rather than against a catalogue.
- Reverse engineering from a worn part, with no drawing required
- On-site 3D scanning where the component cannot be removed
- Material grade selected against your feed rather than a default
- Pattern retained afterwards, so repeat orders skip pattern making
Fitting And Getting The Life Out Of It
- Send photographs and main dimensions for an initial assessment
- Ship the worn sample, or arrange an on-site 3D scan
- Confirm the material grade against the application before pouring
- Approve the CPSS result and pattern before moulding
- Keep the dimensional report for repeat orders
Reverse Engineered Wear Castings At The Foundry
Parts Usually Ordered Alongside This One
Grinding Roller
Mill grinding rollers supplied to the Chinese electric power industry
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Mill Liner
Mill liners in manganese and high chromium for grinding circuits
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Main Shaft Assembly
Complete main shaft assemblies supplied to European customers
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VSI Rotor Body And Frame
Complete rotor bodies for Barmac type and CV series machines
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Reverse Engineered Wear Castings Questions
I have no drawing at all. Can you still make the part?
Yes, and that is the normal starting point. We work from the worn sample, or visit your site for 3D scanning where the part cannot be removed.
Do you charge for pattern making?
Patterns for genuinely new parts are quoted with the job. Where we already hold a finished pattern there is no pattern cost and the lead time is shorter.
What is the heaviest part you can pour?
Up to 10 tonnes as a single casting.
Can you make one part, or is there a minimum?
Single parts and prototypes are regular work here. Tell us the quantity with the enquiry and it is quoted accordingly.
Get A Price For Reverse Engineered Wear Castings
Send the machine model, the part number if you have one, and the quantity. If you have neither, a photograph with the main dimensions is enough to start.