Glossary

Cast Iron

Ferrous alloy with a carbon content above 2%, typically between 2.5% and 4%. The carbon present in excess of its solubility in austenite gives cast iron specific properties of castability, vibration damping and thermal conductivity, making it suitable for producing complex components through casting.

High-Silicon Cast Iron

Ductile (spheroidal graphite) cast iron with a high silicon content (>3.2%) that improves machinability, impact resistance and fatigue behaviour without the need for heat treatment. The main grades are EN-GJS-450-18, EN-GJS-500-14 and EN-GJS-600-10.

Standard: EN 1563

ADI Cast Iron (Austempered)

Ductile cast iron subjected to austempering heat treatment (austenitising followed by rapid cooling in an isothermal bath). The process creates an ausferritic (austenitic-bainitic) microstructure that gives extremely high mechanical strength (up to 1400 MPa), high toughness and wear resistance. Used in gearboxes, gears and automotive components.

Standard: EN 1564, ASTM A897, ISO 17804

Chromium Wear-Resistant Cast Iron (Nihard)

High-alloy white cast iron with chromium (9–27%) and, in some variants, nickel (4–5%). Its predominantly carbide-martensitic structure gives exceptional hardness (>600 HB) and abrasion resistance. Brittle and difficult to machine, it is used in augers, mill linings, cement pumps and earthmoving equipment.

Standard: EN 12513, ASTM A532, ISO 21988

Austenitic Nickel Cast Iron (Ni-Resist)

Alloyed cast iron with a high nickel content (18–36%) that gives it an austenitic structure stable at room temperature. It offers excellent corrosion resistance, high-temperature resistance (up to 850°C) and low thermal stresses. Used for compressor stators, manifolds and pumps handling corrosive liquids. Produced in accordance with EN 13835 and ASTM A436/A439.

Standard: EN 13835, ASTM A436, ASTM A439

Grey Lamellar Cast Iron — GJL

Cast iron in which the excess carbon is present in the form of graphite flakes distributed within the metal matrix. The flakes give the material excellent vibration damping, good machinability and good thermal conductivity. Mechanical strength is limited by the discontinuous shape of the graphite. Produced in accordance with EN 1561 in grades EN-GJL-200, GJL-250, GJL-300, GJL-350.

Standard: EN 1561

SiMo Cast Iron

Ductile cast iron with a high silicon (4–5%) and molybdenum (0.5–1%) content, designed to resist oxidation and retain good mechanical properties at high temperature (up to 700–730°C). Used in the production of exhaust manifolds for automotive and marine engines. Produced in accordance with EN 16124.

Standard: EN 16124, ASTM A1095

Ductile (Spheroidal Graphite) Cast Iron — GJS

Cast iron in which the graphite occurs in nodular (spherical) form due to the addition of magnesium (or cerium) during pouring. The spheroidal shape of the graphite eliminates the notch effects typical of flake graphite, giving higher tensile strength, ductility and toughness than grey cast iron. It is the most versatile material produced by Fonderie Palmieri, available in a wide range of grades from EN-GJS-350 to EN-GJS-800.

Standard: EN 1563, ASTM A536, ISO 1083

Compacted Graphite Cast Iron — GJV

Cast iron in which the graphite takes on a shape intermediate between flake and nodular: compacted (vermicular). It combines the mechanical strength and ductility of ductile cast iron with the thermal conductivity and damping of grey cast iron. Used mainly for cylinder heads, engine blocks and components subject to high thermal cycling.

Standard: EN 16079, ISO 16112, ASTM A842

Core

An element made of agglomerated sand placed inside the mould to create cavities, holes or internal geometries in the casting that would not be achievable with the external shape alone. Cores are produced using Cold Box technology, which uses polyurethane resins cured with amine gas.

Pouring

The stage of the process in which the molten alloy is poured into the mould through the gating system (runners, risers, vents). Controlling pouring temperature, filling speed and flow is critical to avoid defects such as porosity, shrinkage and inclusions.

Radiometric Control

A check carried out on incoming raw materials using radioactivity detectors to identify any contaminated metal. It is a mandatory safety requirement for foundries when accepting metal scrap.

Stress Relieving / Stabilising

A heat treatment that heats the casting to a sub-critical temperature (450–600°C) to reduce internal residual stresses generated during solidification and cooling. It does not alter the microstructure but improves dimensional stability over time, which is essential for precision components.

Engineering / Simulation

A technical activity carried out prior to production, including: casting feasibility analysis, gating system design, and computerised simulation of mould filling and solidification (using software such as MAGMASOFT or FLOW-3D) to predict and prevent defects before the physical casting is produced.

Moulding

The process of preparing the sand moulds into which the molten metal is poured. Automatic moulding with Savelli-Formimpress systems ensures dimensional accuracy, repeatability and reliability across production runs. The mould consists of two half-shells (upper and lower flask) and, where required, cores for internal cavities.

Medium-Frequency Induction Furnace

An electric furnace that melts metal using currents induced by a varying magnetic field. It operates at frequencies of 150–500 Hz and provides high energy efficiency, precise control of chemical composition and flexibility in batch management. Fonderie Palmieri uses Otto Junker furnaces with the INDUGA JUNKER PUMA PRO 1500 system, with a capacity of 5 tonnes per batch in 48 minutes.

Casting

The production process whereby molten metal is poured into a mould to obtain a component of the desired geometry. In foundry work, iron casting involves: raw material preparation, melting in the furnace, alloy treatment, pouring into the mould, solidification, shakeout and finishing.

Testing and Analysis Laboratory

An in-house facility that performs destructive and non-destructive tests on castings to verify their compliance with requirements. Tests typically carried out in a foundry include: chemical analysis (spectrometry), metallographic analysis (microscopic structure), tensile testing, hardness testing, impact testing, dimensional checks, dye penetrant testing, radiography (X-rays) and ultrasonic testing.

Machining

Chip-removal operations (turning, milling, drilling, grinding) performed on the rough casting to bring it to final dimensions and the required surface finish. Fonderie Palmieri offers this service through partnerships with qualified Italian machine shops.

Riser

A reservoir of liquid metal connected to the casting that compensates for volumetric shrinkage during solidification by feeding molten metal into the part. Correctly designing the riser system is essential for obtaining castings free of shrinkage porosity.

Metallography

Microscopic analysis of the internal structure of a metallic material, carried out on samples that are polished and etched with chemical reagents. In cast iron, it is used to check the shape, distribution and percentage of graphite, the matrix structure (ferritic, pearlitic, austenitic) and the absence of microstructural defects.

Pattern Shop

The set of patterns (physical replicas of the component) and core boxes used to produce the moulds. Correct tooling design, including the study of the gating system and draft angles, is critical for dimensional quality and productivity. Fonderie Palmieri manages over 2,000 tooling sets in its archive.

Annealing

A heat treatment that softens the material’s microstructure to improve machinability and reduce hardness. In cast iron, subcritical annealing transforms pearlite into ferrite without crossing the critical range; full annealing involves austenitising followed by controlled slow cooling.

Sand Blasting / Shot Blasting

A surface cleaning process for castings using the high-speed projection of metal shot (shot blasting) or abrasive sand. It removes sand residues, oxides and slag from the casting surface. Fonderie Palmieri uses a DISA CT3 blasting machine for mass production and a BANFI monorail shot-blasting system for complex or delicate parts.

Fettling / Deburring

A finishing operation that removes flash, risers and residual gating from the casting after solidification and shot blasting. Fonderie Palmieri has 4 automatic KOYAMA centres (up to 30 kg), a Maus 1200 system for heavy castings, and manual fettling booths for parts from 10 to 300 kg.

Flask

A rigid metal frame that holds the compacted sand during moulding. The upper (cope) and lower (drag) flasks are joined together to form the cavity into which the molten metal is poured. A large stock of flasks makes it possible to decouple the moulding cycle from solidification, increasing productivity.

3D Printing for Cores (Binder Jetting)

A rapid prototyping technology that produces sand cores directly from CAD files without the need for physical tooling (core boxes). The ExOne system adopted by Fonderie Palmieri deposits a selective binder layer by layer onto the sand, enabling the production of complex geometries that would be impossible with traditional moulding. It drastically reduces sampling times.

Cold Box Technology

A core production process in which sand is mixed with two-component resins (polyol + isocyanate) and cured by blowing amine gas at room temperature. It provides high mechanical strength, a good surface finish and low gas emissions during pouring compared to hot-box processes.

Heat Treatment

A set of controlled heating, holding and cooling cycles applied to castings to modify their microstructure and mechanical properties. Fonderie Palmieri has 3 furnaces with capacities of 3, 6 and 12 m³. Treatments performed include: stress relieving/stabilising, subcritical annealing, full annealing, destabilisation of chromium cast irons, air hardening, normalising and graphitising.

AIA — Integrated Environmental Authorisation (IPPC — Integrated Pollution Prevention and Control)

An authorisation required under Italian law (Legislative Decree 152/2006, implementing the IPPC Directive) for industrial plants with a potentially significant environmental impact. For foundries with production capacity above certain thresholds, the AIA sets emission limits, monitoring requirements and the Best Available Techniques (BAT) to be adopted.

ASTM — American Society for Testing and Materials

An American standards body that publishes technical standards for materials, products and systems. Many international customers require compliance with ASTM standards as an alternative or in addition to EN standards. For ductile iron, the main reference is ASTM A536; for grey iron, ASTM A48; for ADI, ASTM A897.

BAT — Best Available Techniques

Production and pollution-control techniques that represent the state of the art in preventing and reducing industrial emissions. BAT for foundries are defined in the European BREF documents and constitute the technical reference for AIA authorisations.

Bureau Veritas Naval Approval for Cast Iron

Certification issued by Bureau Veritas (BV), an international classification society, for the production of cast iron intended for the shipbuilding industry. It attests to the compliance of materials, processes and the quality system with the technical requirements of naval construction, enabling supply to shipyards and international shipowners.

DNV-CP-0249 Naval Certification

Approval issued by Det Norske Veritas (DNV), an international naval classification society, certifying the foundry’s compliance with the requirements for producing components intended for the naval and offshore industry. It requires compliance with specific metallurgical standards, dedicated quality systems and approval of the testing laboratory. Fonderie Palmieri is DNV certified.

Circular Economy

An economic model that aims to eliminate waste and keep resources in use for as long as possible through reuse, repair and recycling. In foundry work, the circular economy applies to the recycling of ferrous scrap as the main raw material (cast iron is 100% recyclable), the recovery of spent moulding sand and the recovery of slag.

Energy Efficiency

The ratio between the useful energy produced and the total energy consumed in a process. Medium-frequency induction melting is inherently more efficient than traditional cupola furnaces. Fonderie Palmieri optimises consumption through the ISO 50001 management system and the use of heat-recovery technologies.

Environmental Management

The set of activities, procedures and controls adopted to minimise the environmental impact of production processes. In foundry work, this includes: dust and fume abatement systems (bag filters, scrubbers), process water management, treatment of spent sand, monitoring of atmospheric emissions and compliance with environmental authorisations (AIA — Integrated Environmental Authorisation).

ISO 9001:2015 — Quality Management System

An international standard that defines the requirements for a Quality Management System (QMS). It requires process documentation, performance measurement, continuous improvement and a focus on customer satisfaction. Fonderie Palmieri is ISO 9001 certified with accreditation for the production of iron castings.

ISO 14001:2015 — Environmental Management System

An international standard that specifies the requirements for an Environmental Management System (EMS). It requires the organisation to identify the significant environmental aspects of its activities, set improvement objectives and monitor environmental performance. For a foundry, the relevant aspects include atmospheric emissions, management of melting waste and water consumption.

ISO 22163:2023 (IRIS) — International Railway Industry Standard

An international standard for quality management systems in the railway sector, developed by UNIFE (the Association of the European Railway Industry). Based on ISO 9001, it incorporates specific requirements for the rail supply chain, such as product risk management, control of critical processes and continuity of supply. Fonderie Palmieri is IRIS certified, enabling supply to customers in the European rail sector.

ISO 45001:2018 — Occupational Health and Safety Management System

An international standard for Occupational Health and Safety Management Systems (OHSMS). It requires risk assessment, the definition of preventive measures and the promotion of a safety culture. It replaced the previous OHSAS 18001. In a foundry, it is particularly critical for managing the risks associated with molten metal, noise, dust and chemical agents.

ISO 50001:2018 — Energy Management System

An international standard for Energy Management Systems. It requires the identification of significant energy consumption, the definition of baselines, savings objectives and a plan for continuous improvement. For a foundry with high-power-density induction furnaces, energy management is a critical factor for sustainability and economic competitiveness.

EN Standard (European Norm)

A technical standard developed by CEN (Comité Européen de Normalisation) and adopted as a national standard by member states. For iron castings, the main reference EN standards are: EN 1563 (ductile iron), EN 1561 (grey iron), EN 1564 (ADI), EN 13835 (austenitic cast iron), EN 12513 (white and wear-resistant cast irons), EN 16079 (compacted graphite iron), EN 16124 (SiMo cast iron).

Integrated Management Policy

A document that formalises the organisation’s commitments to quality, the environment, occupational health and safety, and energy. It sets out the guiding principles, strategic objectives and the framework for continuous improvement across all management systems. For Fonderie Palmieri, it represents the reference framework for integrating the ISO 9001, ISO 14001, ISO 45001 and ISO 50001 systems.

Traceability

The ability to reconstruct a product’s history throughout the entire supply chain: from the raw material supplier, through the process parameters, to the end customer. In a foundry, this is achieved through the recording of raw material test certificates, melting parameters, casting test results and any heat treatments applied.