Manufacturing Process
How a centrifugally cast cylinder liner is made
The raw material is a controlled combination of pig iron, mild steel, selected iron scrap and cast iron. Proportions are chosen for each application according to the properties required by the matching components and the specification of the original equipment manufacturer.
The charge is melted in an induction furnace under controlled electrical supply — high ampere, low voltage — held for a specified time and brought to a melting temperature of 1,400–2,000 °C.
A sample is drawn and tested for composition before pouring. Carbon, manganese and silicon are verified on our in-house Hitachi Foundry-Master Smart 2 optical emission spectrometer, which covers all ferrous grades.
Sulphur and phosphorus are held within permissible limits. Slag is removed, then additives — nickel, molybdenum, chromium and copper — are introduced in small, specified quantities to develop the required strength, hardness and surface finish. The molten metal is then transferred to ladles and poured into rotating dies, where it is cast centrifugally.
We work to a stage-inspection method. Purpose-designed jigs and fixtures act as go / no-go gauges throughout manufacturing. After rough machining, every piece is inspected for casting defects, cracks and sufficient material thickness wherever further machining is required.
Hardness is then checked on every piece using a Brinell hardness tester. Finished liners are inspected, stamped with the MDT or JAI NO 1 mark, and dipped in anti-corrosion agents to protect them in storage and transit.
Inspection & Quality Control
Verified composition, dimensions and metallurgy
Chemical Composition
| Limit | C | Si | S | Mn | Ni | Cr |
|---|---|---|---|---|---|---|
| Min | 3.10 | 1.60 | 0.03 | 0.3 | 0.005 | 0.006 |
| Max | 3.70 | 2.70 | 0.1 | 1.0 | 0.5 | 0.4 |
Values shown as percentages. Compositions can be adjusted to customer specification and are verified on every heat before casting is released.
Dimensional Tolerances
Finished centrifugally cast cylinder liner:
| Parameter | Acceptance criteria |
|---|---|
| Length | ± 0.2 mm |
| Outer diameter (finish face) | ± 0.025 mm |
| Outer diameter (second face) | ± 0.1 mm |
| Inner diameter | ± 0.025 mm |
| Collar diameter | ± 0.025 mm |
| Collar width (finished) | ± 0.05 mm |
| Collar width (semi-finished) | ± 0.1 mm |
Mechanical & Metallurgical Properties
| Hardness | 190 – 260 BHN |
| Tensile strength | 22 – 25 kgf/mm² |
| Surface roughness | 0.4 – 0.8 micron |
| Microstructure | Graphite Type A and B (D and E random) |
| Flake size | 4 – 8 maximum |
| Matrix | Free ferrite, maximum 5–6% |
Graphite structure, microstructure phases and nodularity are examined under a metallurgical microscope. All instruments are calibrated by certified agencies under our ISO 9001:2015 system.
More on How We Manufacture
“At Jaidarshan, we nurture excellence in technology.”
Call or WhatsApp: +91 93779 67468
Email: info@engineliner.com