Duplex Alloy Castings Manufacturer
Heavy-duty steel castings for challenging environments
Mangal Steel Castings manufactures duplex alloy castings for OEMs and tier-1 suppliers in valves, pumps, and other demanding industries. These austenitic-ferritic alloys are desirable where strength and corrosion resistance take precedence to achieve optimal performance. We pour ASTM A890- and ASTM A995-grade duplex stainless steel and super duplex stainless steel to cast a range of components.
Duplex alloys aren’t very machinable—which is where we come in. Our precision casting process delivers near-net shape that reduces machining requirements and total cost of ownership.
PPAP
IATF 16949
ISO 9001:2015
Pan-India Supply
Global Export
Build Corrosion-Resistant Components With Duplex Alloy Precision
Get duplex stainless steel castings manufactured to meet demanding strength, toughness, and corrosion-resistance requirements.
Duplex Alloys We Support
We source, melt, and pour the following grades across A890 and A995 to create durable duplex alloy castings.
ASTM A890 (General Corrosion Resistance)
| ASTM Grade | Alloy Category | ACI Designation | UNS Cast Number | Wrought Equivalent(UNS) | Nominal Composition | Typical PREN |
|---|---|---|---|---|---|---|
| 1B | Duplex | CD4MCuN | J93372 | S32550 (Ferralium 255) | 25Cr – 5Ni – 2Mo – 3Cu – N | ~33 – 36 |
| 1C | Duplex | CD3MCuN | J93373 | S32550 variant | 25Cr – 5.5Ni – 2Mo – 3Cu – N | ~33 – 36 |
| 2A | Duplex | CE8MN | J93345 | S31200 | 24Cr – 9.5Ni – 2Mo – N | ~31 – 34 |
| 3A | Duplex | CD6MN | J93371 | S32550 (no Cu) / 255 Base | 25Cr – 5.5Ni – 2Mo – N | ~33 – 35 |
| 4A | Standard Duplex | CD3MN | J92205 | S31803 / S32205 (2205) | 22Cr – 5Ni – 3Mo – 0.2N | ~34 – 36 |
| 5A | Super Duplex | CE3MN | J93404 | S32750 (2507) | 25Cr – 7Ni – 4.5Mo – 0.2N | ~42 – 44 |
ASTM A995 (Pressure-containing parts)
| ASTM Grade | Alloy Category | ACI Designation | UNS Cast Number | Wrought Equivalent | Nominal Composition | Typical PREN |
|---|---|---|---|---|---|---|
| 1B | Duplex | CD4MCuN | J93372 | S32550 (Ferralium 255) | 25Cr – 5Ni – 2Mo – 3Cu – N | ~33 – 36 |
| 2A | Duplex | CE8MN | J93345 | S31200 | 24Cr – 9.5Ni – 2Mo – N | ~31 – 34 |
| 3A | Duplex | CD6MN | J93371 | S32550 (no Cu) / 255 Base | 25Cr – 5.5Ni – 2Mo – N | ~33 – 35 |
| 4A | Standard Duplex | CD3MN | J92205 | S31803 / S32205 (2205) | 22Cr – 5Ni – 3Mo – 0.2N | ~34 – 36 |
| 5A | Super Duplex | CE3MN | J93404 | S32750 (2507) | 25Cr – 7Ni – 4.5Mo – 0.2N | ~42 – 44 |
Note: PREN = Pitting Resistance Equivalent Number. Value ≥ 40 is Super Duplex.
Our Range of Duplex Alloy Castings
We manufacture the following components using the above-listed duplex and super duplex castings.
| Vertical | Duplex alloy castings |
|---|---|
| Valve components | Body, Bonnet, Closure members (Ball, Disc, Wedge, Gate), Stem, Seats & trims, Packing, Gaskets |
| Pump components | Casings, Volutes, Impellers, Shafts, Diffusers, Mechanical seal faces |
| Oil and gas components | Pump impellers, Diffusers, Inducers, Valve gates and closure members, Trims |
| Defense (Naval) | Seawater pump components, valve bodies. Ballast, heat-exchanger housings |
| Pulp and Paper | Digester components, Bleaching vessel fittings, Impellers |
| Mining and Minerals | Slurry pump casings, Hydrocyclone components, Agitator blades |
| Food and Beverage | Agitator components, Mixing tanks, Heat-exchanger components |
Technical details
Key data for our duplex alloy castings, from weight and dimensions to heat and surface treatment.
| Particulars | Details |
|---|---|
| Process | Investment casting, Lost-wax casting, Feinguss casting |
| Shell building material | Ceramic, Stucco |
| Weight range | 20 grams to 90 kg |
| Max. dimension range | 500 mm x 500 mm x 400 mm |
| Wall thickness range | 0.5 – 5 mm |
| Tolerance | VDG P690, ISO 8062, IS 1116 |
| Machining allowance | 0.2 mm – 1 mm |
| Heat treatment | Solution annealing, Quenching, Air cooling, Tempering |
| Surface treatment | Sandblasting, Shot blasting, Electroplating, Polishing |
| Compliance & standards | ASME A890, ASME A995, SA-995, API 610, EN 10283, ISO 11974, ISO 15156, ISO 13709, IS 9650 |
Source Duplex Alloy Castings Built for Demanding Conditions
Partner with an experienced foundry for precision duplex castings tailored to your material grade, design, tolerances, and application.
Our Duplex Alloy Casting Process
Casting with duplex alloys, including super duplex, necessitates adjustments. Here, we detail the modifications we make to ensure our castings achieve product-application fit.
Moulding
Injecting liquid wax at a steady rate into engineered dies to create the part pattern. Multiple part patterns are oriented, aligned, and affixed to a sprue to create a cluster.
Investing
Dipping the cluster in the slurry pot and then in a rainfall sander. This process repeats up to ten times to create optimal shells. We use alumina or zircon for the first two to three face coats and then shift to silica.
Dewaxing & Heating
Placing the cluster in an autoclave where steam melts the wax. Next, the cast is placed in a furnace to remove moisture and residual wax.
Melting & Pouring
Melting the duplex alloy, placing it in the AOD to ensure optimal nitrogen levels, and quickly pouring it to ensure minimal nitrogen loss.
Knocking & Fettling
Breaking the shell using pressurized water jets, sawing off the individual parts from the sprue, and grinding away the gate and runners.
Heat treatment
Introducing the as-cast components into a pre-heated furnace to heat them to 1100°C for solution annealing, followed by rapid water quenching. This step is critical to ensure sigma-free duplex alloy castings.
Machining
Planning the machining outlay, and then milling and reaming the mating surfaces and critical surfaces for tight tolerances.
Inspection & Dispatch
Hardness, toughness, Charpy V-notch impact test, Spectrographic and other NDT tests before shipping to the port of destination.
Why Choose Mangal Steel Castings for Duplex Alloy Castings
Our leadership team brings more than 45 years of cumulative casting experience and expertise to the table. It’s a big reason why OEMs and tier-1 manufacturers across the board trust us with their duplex alloy castings. Other reasons include:
- Rapid prototyping: Master CAM, SolidWorks, and 3D printing to quickly iterate on complex designs and engineer a prototype in 5 days.
- Quality sourcing: Pre-approved list of suppliers who supply us with quality raw materials. We do not accept lots without mill test certificates.
- Modern foundry: Semi-automatic top- and side-injecting wax injection machines, rainfall sander, 350kw furnace, Tumblast shot blasting machines, Bruker-make OES machine; modern processes, and built-in quality control.
- Volume production: ~950 MT annual production with the capacity to produce at ramp up production during peak demand seasons.
- Certifications: ISO 9001:2015, AD 2000 Merkblatt W0, PED 2014/68/EU, IBR
- Robust documentation: Mill test certificates, OES test reports, AOD report, NDT report, TDS, and all other necessary documents as required.
- Turnkey casting: End-to-end solution for duplex alloy casting to reduce supply chain complexities and drive quality control.
- Export compliance: International supply regulation-conscious for all leading destinations including the U.S.A., Canada, Mexico, the U.K., France, Germany, Poland, the Netherlands, Italy, Romania, South Africa, the U.A.E., Saudi Arabia, Sri Lanka, Japan, Australia, and New Zealand.
- ESG awareness: Self-hosted solar power plant, green manufacturing processes, and other green initiatives to lower carbon footprint.
Engineer Superior Performance With Duplex Alloy Castings
Get precision castings designed for high strength, corrosion resistance, and demanding industrial applications.
Industries We Support with Duplex Alloy Castings
- Valves
- Pumps
- Petroleum & Chemicals
- Paper & Pulp
- Oil & Gas
- Earth moving
- Mining & Minerals
- Defence (Naval)
- General Engineering
- Food & Beverage
- Pipes
Frequently Asked Questions
Do you produce duplex alloy castings using the 6A grade?
No, currently we do not support 6A grade for casting. Our processes are designed to offer support for up to 5A, which handles most requirements.
Can you cast with our proprietary duplex alloy?
We are confident of successfully casting with proprietary duplex alloys as long as the metallurgy is aligned with 5A. We do not support 6A at the moment.
What are your lead times for duplex alloy castings?
Duplex alloy casting lead times are between 30 and 40 days for the first dispatch. Subsequent dispatches take less time.
Why choose duplex alloy casting instead of SS 316L?
Duplex alloys have nearly twice the strength of 316L stainless steel. This translates to lower weight, thinner walls, and overall savings. However, 316L is better suited to high temperatures.
How do duplex alloys compare to SS 300 and SS 400 series?
Duplex is roughly a 50/50 mix of austenitic and ferritic to deliver increased strength and corrosion resistance. 300 series (austenitic) has excellent corrosion resistance but low strength. 400 series (ferritic) has better strength but is pricey. Duplex is the best of both worlds.
What is your MOQ for duplex alloy castings?
Our MOQ for duplex alloy castings is largely contingent on material, design, and delivery destination. Please get in touch for a bespoke quote.
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