Case study: cast iron solutions for critical components
Real-life case studies illustrating the development of components and solutions for various sectors
Case studies of components developed for off-highway, on-highway, industrial and automotive applications
We present a collection of case studies that illustrate the design approach, construction methods, applications and benefits of the solutions developed by Zanardi Fonderie in response to specific technical requirements set out by our clients. The projects presented cover components for various sectors, including off-highway, on-highway, automotive, industrial and hydraulic, offering a practical overview of the solutions adopted in different manufacturing contexts.
Railway Brake Lever in ADI 800-10
This case study describes the conversion of a railroad brake lever from forged steel to ADI 800-10 austempered spheroidal cast iron: lower weight and reduced production costs, while meeting the mechanical performance requirements of the brake assembly.
Excavator coupler in IDI800
The case history describes the optimization of an excavator coupler through a material upgrade to isothermal ductile iron IDI800, developed in partnership with Härenviks. The conversion meets the requirements of a safety-critical application, delivering superior mechanical performance and higher safety margins.
Hydraulic valves made of spheroidal graphite cast iron (GJS)
This case study describes the use of spheroidal graphite cast iron (GJS), in pearlitic grades, in place of traditional GJL for hydraulic distributors in off-highway machinery. The material combines resistance to pressure and cyclic loads, design flexibility for internal passages, and long-term metallurgical reliability.
AGI Impeller for Hydraulic Pumps
The case history illustrates the upgrade of a GJL 200 gray cast iron hydraulic pump impeller through austempering. Converting the component to Austempered Gray Iron (AGI) maximizes abrasive wear resistance without requiring modifications to the original casting or the production process.
Engine Base: Upgrade with Austempering
This case history describes the upgrade of a gray cast iron GJL 250 engine block through austempering, resulting in Austempered Gray Iron (AGI): improved performance without changes to geometry or production.
Uniball for DAC system
The UNIBALL project, developed by Zanardi Fonderie for the DAC system, introduces the use of ADI cast iron to lighten the component, simplify production, and reduce environmental impact. Part of the MOST program, it represents a concrete step towards more efficient and sustainable rail mobility.
Attachment frame for snow groomer
The case history presents the optimization of an articulated joint for snow groomers, initially made of S355J2 steel, through the use of austempered ductile iron ADI1050-6. The conversion resulted in a stronger, lighter monolithic component with a simplified manufacturing process.
Lower suspension arm in ADI900-8
Description of a new lower suspension arm for the on-highway sector, designed from the outset using ADI900-8 austempered spheroidal graphite cast iron to be lighter, stronger and more high-performing than traditional forged steel.
Axle pin
Manufacture of an axle pin for off-highway applications, previously made from welded steel, now produced from ADI cast iron for modular vehicles, trailers and self-propelled vehicles used for handling heavy loads.
Planetary housing
How we re-designed and developed a planetary housing for planetary gear reducers using ADI ductile iron instead of nitrided cast iron.
Track axle
Description of the process of conversion to ADI ductile iron of a track axle for combine harvesters with benefits in terms of cost savings, weight and performance.
Hydraulic head
Development and production of a hydraulic head in IDI800-6 isothermal ductile iron for water-driven high-pressure piston pumps, for the steel and iron, chemical and petrochemical, construction and water treatment industrial sectors.
Hollow shaft
The hollow shaft for wheel balancers is used specifically to produce Corghi wheel balancers.
ADI suspension arm – steel
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