Facts about ULDALL

We manufacture customised cast iron components weighing from 0.5 to 4,000 kg and ranging in size from approx. 100 mm to 6,200 mm. We have both internal and external resources that we make available from the design phase onwards. We always encourage our customers to involve us at the engineering stage so that even prototypes incorporate the optimum conditions for subsequent production or mass production.

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At ULDALL, the casting process is adapted to the size, geometry, material and technical requirements of each individual component.
The process typically begins with the design and engineering of the component, after which the casting pattern is produced and used to create a sand mould in chemically bonded sand. If the component requires cavities or hidden geometries, sand cores are used in the mould.

The molten iron is poured manually and flexibly into the mould using casting ladles. Once the iron has solidified, the component is separated from the sand, after which it is cleaned and ground. If required, the cast iron component can also be machined and surface treated so that it is delivered ready for assembly in the customer’s subsequent production.

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Yes. ULDALL offers the development and production of prototypes and has a Fast Lane Prototyping solution for existing customers. Standard casting patterns and precise cast prototypes can, for relevant projects, be delivered within 2–4 weeks, helping the customer reduce time to market.

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ULDALL manufactures cast iron components in 55 different cast iron alloys and provides advice on material selection based on the component’s function and technical requirements. We work with, among others, grey cast iron (EN-GJL), ductile iron/nodular cast iron (EN-GJS), as well as special alloys such as Ni-Hard, Ni-Resist and heat-resistant SiMo cast iron.

The different cast iron alloys have different properties in terms of, among other things, strength, toughness, wear resistance, vibration damping, corrosion resistance, heat resistance and machinability. Material selection is therefore an important part of the development of each individual cast iron component. ULDALL’s flexible production also makes it possible to manufacture customised alloys for specific customer requirements.

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Yes. ULDALL can coordinate machining of cast iron through local specialists and the combined capabilities of BIRN Group. This is relevant for customers who require machined cast iron components and assembly-ready components rather than raw castings.

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Yes. ULDALL offers surface treatment of cast iron as part of our assembly-ready cast iron solutions. We have our own painter who can carry out wet painting of cast iron components.

If the component requires other types of surface treatment, we work with specialised external suppliers. This provides access to processes including powder coating, nickel plating, electrophoretic coating (E-coating) and zinc phosphating.

Surface treatment can be combined with quality control and machining, enabling the customer to receive a finished, assembly-ready cast iron component that can go directly into production.

ULDALL carries out quality control of the cast iron as an integrated part of production. We inspect and analyse the molten iron and, when producing ductile iron (EN-GJS), monitor the treatment that ensures the required spheroidal graphite structure.

Depending on the requirements of the customer and the component, quality control may also include microscopic analysis, magnetic particle testing and ultrasonic testing. We can also provide a certificate documenting the mechanical properties of the cast iron for marine and industrial applications.

Quality control can be combined with machining and surface treatment, providing the customer with an integrated solution and a quality-controlled, assembly-ready cast iron component.

Already in the design phase, it may be relevant to consider whether a component should be manufactured as a cast iron solution rather than as a construction consisting of metal parts that are subsequently welded together. ULDALL provides advice on engineering and casting techniques and can help assess whether cast iron is the right solution based on the component’s function, geometry, load and production volume.

For components that need to withstand high loads and have demanding requirements for strength and wear resistance, cast iron can offer significant advantages. A cast construction also provides greater design freedom and the possibility of creating geometries and wall thicknesses tailored to the function of the component.

In some cases, a cast solution can also provide a longer service life, reduce the risk of leaks and material degradation from welds, and lower the total costs of production and operation. It can therefore be worthwhile to consider casting early in the product development process, before the design and production method have been determined.

Read more about the advantages of switching from a welded construction to a cast iron solution.

ULDALL manufactures cast iron components for a wide range of industries, including marine, energy, food, agriculture and general industry. The solution is always adapted to the industry’s requirements for quality, environmental impact and operation.

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Customers choose ULDALL when total cost of ownership (TCO) is important and when they also need a flexible development and production partner for complex cast iron components, prototypes and small series.

Our engineering support, broad materials expertise and ability to provide assembly-ready solutions give the customer one integrated process from idea to finished component.

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