SPECIAL STEEL CASTINGS

The specialists for form and function

OUR COMPANY

WE LOVE WHAT WE DO

Our plants in Ründeroth, Weiershagen

and Dieringhausen (on the right)

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Dörrenberg worldwide

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2 6
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1 Dörrenberg Edelstahl, Germany –

(plants in Ründeroth, Dieringhausen, Weiershagen and Herford))

2 Dörrenberg Tratamientos 3 Doerrenberg Special Steels 4 Doerrenberg China –

Térmicos Spain – Singapore – tool steel tool steel
vacuum-hardening, plasma-nitriding

5 Doerrenberg Taiwan – 6 Doerrenberg South Korea –

tool steel tool steel

History
For generations Dörrenberg has been synonymous with manufacturing and finishing
of high-grade steels. The company’s origins stretch back over 300 years.

ƒ 1860 Registration as a forge and steel mill
ƒ 1932 Establishment of the high-grade steel foundry
ƒ 1959 Establishment of the surface finishing division
ƒ 1977 Establishment of the investment casting foundry
ƒ 1990 Organisation split into four business divisions
ƒ 1996 Dörrenberg becomes a part of Gesco AG
ƒ 2005 Commissioning of Weiershagen plant
ƒ 2005 Conversion of the foundry plant Ründeroth
ƒ 2007 Expansion of heat treatment facility plant Ründeroth
Oelchens Hammer
ƒ 2008 Commissioning of plant Herford
ƒ 2010 Expansion of plant Weiershagen
ƒ 2010/2011 Expansion of steel mill plant Ründeroth
ƒ 2011 Expansion of fettling shop plant Ründeroth
ƒ 2011/2012 Expansion of plant Weiershagen
ƒ 2013 Commissioning of plant Dieringhausen

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OUR CAPACITIES

Moulding

Our moulding facility is equipped with three conventional man- ƒƒ 3ƒcoreƒshooters

ual moulding lines. We use furan-resin-bonded moulding
ƒƒ Core-makingƒusingƒmanualƒmouldsƒupƒtoƒaƒweightƒofƒ4ƒt
materials. Small batches are manufactured as cost effectively
as individual components with a unit weight of up to 12 tonnes. ƒƒ 3
ƒ ƒmanualƒmouldingƒlines,ƒboxƒsizeƒmax.ƒ4500ƒxƒ2200ƒmmƒ
A state-of-the-art sand preparation facility guarantees optimum (circular:ƒ2200ƒmm,ƒsquare:ƒ3000ƒxƒ3000ƒmm)
economical and technical utilisation of the raw materials used. ƒƒ Productionƒofƒsandƒmouldsƒbyƒusingƒsandƒprintƒmachine
Since most recently we offer the possibility to scan and digitalise
existing castings and subsequently construct sand moulds using
patternless sand prints. This process is ideal for manufacturing
replacement parts, individual components and small batches.

Foundry

State-of-the-art furnaces and continuous enhancement guaran- ƒƒ ƒWeƒproduceƒapprox.ƒ200ƒdifferentƒmaterials

tee a high degree of manufacturing reliability. The range includes:
ƒƒ C
ƒ astingsƒupƒtoƒaƒdeliveryƒweightƒofƒapprox.ƒ12,000ƒkgƒ
ƒ Corrosion- and acid-resistant steels (material-dependent)
ƒ Duplex and super-duplex steels
ƒƒ 4ƒinductionƒfurnacesƒ(1.0ƒt;ƒ1.2ƒt;ƒ2.4ƒt;ƒ3.5ƒt)
ƒ Tool steels
ƒ Heat-resistant steels ƒƒ 1ƒelectricƒarcƒfurnaceƒ10ƒt
ƒ Wear-resistant steels ƒƒ 1ƒplasma-ladleƒfurnaceƒ15ƒt
An end-to-end ERP system from initial weighing to certification
ensures certified production.

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ƒ 2 large Arc air burner stations
ƒ Various grinding facilities
ƒ Various blasting booths
ƒ 3 bogie hearth furnaces up to 4,500 x 3,000 x 1,800 mm
ƒ Large water tank with counterflow system
ƒ Various vacuum furnaces
ƒ Pit furnaces, bell furnaces
ƒƒ 8ƒcentreƒlathesƒCNC/conventionalƒupƒtoƒØƒ1,200ƒmm
ƒƒ 4
ƒ ƒverticalƒturningƒandƒboringƒmachinesƒCNC/ƒ
conventionalƒupƒtoƒØƒ2,700ƒmm
ƒƒ 6
ƒ ƒmillingƒmachines/boringƒmillsƒCNC/ƒ
conventionalƒupƒtoƒ2,000ƒxƒ1,600ƒmm/؃1,500ƒmm
ƒƒ 6
ƒ ƒgrindingƒmachinesƒCNC/ƒ
conventionalƒupƒtoƒØƒ1,000ƒxƒ800ƒmm
ƒƒ Slottingƒandƒkeyseatingƒmachines
ƒƒ Scanningƒandƒmeasuringƒequipment
Fettling shop/heat treatment
Fettling reveals castings in their true colours. Heat treatment un-
locks the full potential of the materials. Production welding is
monitored by experienced welding engineers. The technology
is qualified to applicable standards and is regularly inspected.
We train our staff on a continuous basis. If required all finishing
procedures up to 1,250 °C can be performed after welding in the
attached heat treatment facility. We use a total of 20 state-of-the-
art furnaces. A large water tank with counterflow system and a
fan cooling system are available for cooling purposes. Manual and
automatic blasting booths guarantee thorough cleaning.
Machining
A wide range of pre-machining and finishing options compliments
the company’s extensive vertical integration. In line with market
requirements we have specifically expanded the range of ma-
chining options.
Modern machining centres process components with diameters of
up to 2,500 millimetres and corresponding machining heights. For
special requirements we cooperate closely with affiliated partners.
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CORROSION- AND ACID-RESISTANT SPECIAL STEEL CASTINGS
Our extensive product portfolio is
applied in the following industries:
ƒ Turbines and pumps industry
ƒ Filtration and centrifuge equipment
ƒ Kneading and mixing equipment
ƒ Food-processing industry
ƒ Paper and pulp industry
ƒ Power station engineering
ƒ Extruder systems
ƒ General plant engineering
ƒ Hydropower plant engineering
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Cast steel is regarded as corrosion-resistant if it features a par-
ticular resistance to chemical impacts. Corrosion resistant steel
castings feature a carbon adjusted chromium content of at least
10.5 %. Stainless steel castings are standardised in accordance with
EN 10213, EN 10283 and SEW 410. All these materials as well as
special services and product enhancements are part of Dörrenberg
Edelstahl GmbH’s standard repertoire. The most important charac-
teristic of these steels is their resistance to corrosion and acids.
Soft-duplex castings (DE material SD Ni4) and the duplex and super-
duplex materials with a pitting resistance equivalent number (PREN)
> 40 feature a particularly high resistance to corrosion as well as a
high basic strength. This cast steel forms the ideal basis for, e.g.
highly stressed, rotationally symmetric castings for decanters and
centrifuges.
Castings resistant to organic and inorganic impacts, are suitable for
use in all kinds of extreme conditions.
 An extensive range of corrosion- and acid-resistant
special steel cast components.

The patented moulding process for open and Chemical Composition

Mat. no. Designation
closed impellers guarantees a particularly C Cr Mo Ni Cu Nb N
high degree of precision. Another speciality 1.4463 GX6CrNiMo24-8-2 ≤ 0.07 24.00 2.25 7.75 – – –

are e.g. hollow-cast kneading blades, which 1.4470 GX2CrNiMoN22-5-3 ≤ 0.03 22.00 3.00 5.50 – – 0.16
can be cooled or heated during application. 1.4417 GX2CrNiMoN25-7-3 ≤ 0.03 25.00 3.50 7.25 – – 0.19

1.4517 GX2CrNiMoCuN25-6-3-3 ≤ 0.03 25.50 3.00 6.00 3.00 – 0.18

Irrespective of whether hollow- or full-mould
1.4340 GX40CrNi27-4 0.40 27.00 – 4.50 – – –
casting – Dörrenberg Edelstahl provides high-
1.4464 GX40CrNiMo27-5 0.40 27.00 2.25 5.00 – – –
est security in the development and design
SD Ni4 Special material ≤ 0.03 23.00 – 4.50 – – 0.12
of special steel castings. The table on the right
G4517.3 Special material ≤ 0.03 26.50 3.70 6.00 3.10 – 0.23
shows an extract of the most important cor-
rosion- and acid-resistant casting materials. 1.4309 GX2CrNi19-11 ≤ 0.03 19.00 – 10.5 – – –
8x%C
1.4552 GX5CrNiNb19-11 ≤ 0.07 19.00 – 10.5 – ≤ 1.0 –

1.4409 GX2CrNiMo19-11-2 ≤ 0.03 19.00 2.25 10.5 – – –

8x%C
1.4581 GX5CrNiMoNb19-11-2 ≤ 0.07 19.00 2.25 10.5 – ≤ 1.0 –

G4529.1 GX3NiCrMoCu25-20-4 ≤ 0.03 20.00 5.60 25.00 0.75 – 0.12

Other materials are available on request.

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WEAR-RESISTANT SPECIAL STEEL CASTINGS

An extensive range of wear-resistant special steel cast

components.

Wear refers to undesirable abrasion on the surface of a material

primarily caused by mechanical interaction with other solids or
Applications for wear-resistant materials
materials. A wide range of different steels are used depending on
the type of abrasion. As a result of many years of experience and include the following:
research in this sector, Dörrenberg Edelstahl provides a range of
selected highly wear-resistant materials for your specific applica- ƒ Straightening, forming and calibrating rolls
tion. In order to select the steel grades, a careful wear analysis is ƒ Press tools
vital. Factors, such as mechanical, dynamic and thermal impact,
ƒ Cutting, forming and drawings tools
as well as ductility requirements play a key role. We provide com-
ƒ Rolls, roll shells
prehensive technical advice for your particular requirements. The
wear resistance is determined by the high special carbide con- ƒ Die-casting facilities, extruders
tent. Additional quenching and tempering develops the material’s ƒ Pump industry
full potential. Hardness and ductility can be accurately set to the
ƒ Mining industry
relevant maximum. One major product in the field of wear-resistant
special steels are cast forming rolls (for pipe mills) and straightening ƒ Cement manufacturing
rolls (for rail and section mills). Using the material GP4M®, enables ƒ Briquetting facilities
complex roll geometries to be realized more easily than using
ƒ General mould- and tool making industry
existing standard materials. The special material GP4M®, is par-
ticularly wear-resistant, durable and extremely resistant to surface

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 Rolls are a major product in the manufacturing
of wear-resistant special steels.

spallation during operational use. With Chemical Composition

Mat. no. Designation
an adjustable working hardness of up to C Si Mn Cr Mo Ni V Co W
approx. 60 HRC, even larger dimensions 1.2382 GX155CrVMo12-1 1.55 0.65 0.50 11.50 0.80 – 1.00 – –

can be through hardened. In addition, we 1.2602 GX165CrMoV12 1.60 0.35 0.30 11.50 0.60 – 0.30 – 0.50
produce press tools for sheet forming and 1.2769 G45CrNiMo4-2 0.45 0.50 0.60 1.00 0.25 0.50 0.10 – –
pre-moulded castings for tool- and mould- 1.4086 GX120Cr29 1.10 1.30 0.85 28.50 – – – – –
making. Dörrenberg Edelstahl provides
G4112 Special material 0.90 0.65 0.65 17.05 1.10 – 0.10 – –
comprehensive technical advice right from
G4122 Special material 0.35 0.65 0.65 16.00 1.10 0.40 – – –
the start. The choice of materials, design
1.7140 G47CrMn6 0.50 0.60 0.80 1.50 – – – – –
and cast visualisation are optimally adjusted
1.7231 G42CrMo4 0.42 0.40 0.70 1.00 0.22 ≤ 0.40 – – –
to the particular application. The table on the
right shows an extract of the most important GP16XR Special material 1.80 0.65 0.50 13.50 0.90 – 0.45 0.75 –

wear-resistant casting materials. GP27M Special material 2.60 0.80 0.70 25.00 0.50 – 0.45 – –

GWP7V Special material 0.50 0.95 0.45 7.90 1.60 – 1.70 – –

GP4M ®
Special material 0.60 0.30 + 5.00 + – + – –

Other materials are available on request.

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HEAT-RESISTANT SPECIAL STEEL CASTINGS

Cast steel is regarded as heat-resistant if it features a particularly

high resistance to the scaling effect of gases at temperatures above
Applications for heat-resistant materials
600 °C. These materials are specified in the EN 10295 and SEW 471
standards. Scaling resistance can be attributed to the chromium con- include the following:
tent in the steel. It increases with the chromium concentration and
can be further increased by adding aluminium and silicon. The higher ƒ Industrial furnace construction
the chromium content, the higher the scaling resistance of the steel. ƒ Sintering plants
ƒ Furnaces
Heat-resistant materials can be divided into three groups: ferritic, aus-
tenitic cast steel grades as well as nickel- and cobalt-based alloys. ƒ Hot forming
The level of oxidation resistance required for general use is achieved ƒ Steel industry
by adding the alloying elements silicon, chromium and nickel. At high
ƒ Cement industry
temperatures up to approx. 1,200 °C, these alloying elements form oxy-
dic protective layers that counteract aggressive impacts on the material
ƒ General power station and plant engineering
and prevent further oxidation. Adding nickel improves ductility and heat
resistance and austenitises the structure.

Long-established special materials are available for specific applications.

These include ready-to-install, pre-assembled screen linings for hot

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 An extensive range of heat-resistant special steel cast
components.

sinter screening in steel mills as well as form- Chemical Composition

Mat. no. Designation
ing tools (mandrels) for fittings manufacturers. C Si Mn Cr Mo Ni Nb Co
0.3 1.0 max. 25.0 max. 3.0
1.4823 GX40CrNiSi27-4 0.5 2.5 1.5 28.0 0.5 6.0 – –
We manufacture mandrels with diameters 1.4339 GX32CrNi28-10 0,25 max. max. 27.0 max. 9.0
0.40 2.0 1.5 29.0 0.5 11.0
ranging from a few millimetres to more than
0.15 0.5 max. 17.0 max. 8.0
1.4825 GX25CrNiSi18-9 0.35 2.5 2.0 19.0 0.5 10.0 – –
1000 millimetres. The maximum delivery
0.3 1.0 max. 21.0 max. 9.0
weight is 12 t, dependent on the particular 1.4826 GX40CrNiSi22-10 0.5 2.5 2.0 23.0 0.5 11.0 – –

design. Many years of manufacturing ex- 0.15 0.5 max. 19.0 max. 13.0
1.4832 GX25CrNiSi20-14 0.35 2.5 2.0 21.0 0.5 15.0 – –
perience in special steel castings and 0.3 1.0 max. 24.0 max. 11.0
1.4837 GX40CrNiSi25-12 0.5 2.5 2.0 27.0 0.5 14.0 – –
forward-looking development of castings
0.3 1.0 max. 24.0 max. 19.0
1.4848 GX40CrNiSi25-20 0.5 2.5 2.0 27.0 0.5 22.0 – –
and materials have played a major role in the
0.3 1.0 max. 24.0 max. 33.0 0.8
success of Dörrenberg Edelstahl. The table 1.4852 GX40NiCrSiNb35-26 0.5 2.5 2.0 27.0 0.5 36.0 1.8 –

on the right shows an extract of the most 1.4865 GX40NiCrSi38-19 0.3 1.0 max. 18.0 max. 36.0 – –
0.5 2.5 2.0 21.0 0.5 39.0
important heat-resistant casting materials. 0.35 1.0 max. 27.0 max. 47.0
2.4879 G-NiCr28W 0.55 2.0 1.5 30.0 0.5 50.0 – –

0.05 0.5 max. 27.0 max. max. max. 48.0

2.4778 G-CoCr28 0.25 1.5 1.5 30.0 0.5 4.0 0.5 52.0
max. max. max. 48.0 max. Residue 1.0 Fe max.
2.4680 G-NiCr50Nb 0.1 1.0 0.5 52.0 0.5 1.8 1.0
Other materials are available on request.

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TOOL STEEL CASTINGS
Range of tool steel casting services:
ƒ Casting technique and materials consultancy
ƒ CAD data exchange with casting technique
modification
ƒ Exporit pattern production by cooperation partners
ƒ Manufacturing of raw castings in alloyed and
non-alloyed cast steel
ƒ Unit weight up to 12,000 kg,
maximum size: 4,300 x 2,000 mm
ƒ Moulding methods (full-mould casting method,
hollow-mould casting method, sand-print method)
ƒ Mechanical base machining
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ForƒDörrenberg,ƒtheƒtermƒ„toolƒsteelƒcastings“ƒrefersƒtoƒalloyedƒandƒ
high-alloyedƒcoldƒandƒhotƒworkƒtoolƒsteelsƒforƒtoolmaking.ƒInnovativeƒ
productionƒprocessesƒandƒtheƒdevelopmentƒofƒtoolƒmaterialsƒmakeƒ
Dörrenbergƒtheƒmostƒimportantƒproducerƒofƒtoolƒsteelƒcastings.
In-depthƒconsultingƒduringƒmethodƒplanningƒandƒdesignƒphaseƒ
enablesƒjointƒtoolƒconcepts.ƒToolsƒwithƒcast-inƒcoolingƒpipesƒforƒ
pressƒhardeningƒorƒcastingsƒofƒfiligreeƒtoolsƒdetermineƒaƒsuccess-
fulƒapplication.
Aƒcrucialƒfactorƒforƒtoolƒlifeƒisƒheatƒtreatment.ƒIfƒappliedƒincorrectlyƒƒ
resultingƒfromƒlackƒofƒknowledge,ƒtimeƒorƒfacilities,ƒprematureƒfailureƒ
isƒlikely.ƒHeatƒtreatmentƒdependsƒonƒtheƒchemicalƒcompositionƒofƒ
theƒmaterialƒandƒtheƒcross-sectionƒofƒtheƒtool.ƒDörrenbergƒEdelstahlƒƒ
offersƒ„FullƒService“ƒwithƒoptimumƒconsultationƒandƒrealisationƒofƒallƒ
necessaryƒmeasures.
Theƒtableƒonƒtheƒleftƒshowsƒanƒextractƒofƒtheƒmostƒimportantƒtoolƒsteelƒ
castingƒmaterials.
 Dörrenberg supplies alloy and high-alloy cold- and
hot-work tool steels.

Chemical Composition
Mat. no. Designation
C Si Mn Cr Mo V W Ni Co
1.2310 G40CrMnMo7 0.40 0.50 1.50 1.90 0.30 – – – –

1.2769 G45CrNiMo4-2 0.45 0.50 0.60 1.00 0.25 0.10 – 0.50 –

1.7140 G47CrMn6 0.50 0.60 0.80 1.50 – – – – –

1.2320 G60CrMoV10-7 0.60 0.50 1.20 2.50 0.70 0.10 – – –

1.2333 G59CrMoV18-5 0.60 0.40 0.80 4.50 0.50 0.20 – – –

GP4M ®
Special material 0.60 0.30 + 5.00 + + – – –

1.2370 GX100CrMoV5-1 1.00 0.30 0.50 5.00 1.00 0.30 – – –

1.2382 GX155CrVMo12-1 1.55 0.65 0.50 11.50 0.80 1.00 – – –

1.2602 GX165CrMoV12 1.60 0.35 0.30 11.50 0.60 0.30 0.50 – –

Cast-in cooling pipe system in a forming tool.

Other materials are available on request.

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THE QUALITY STANDARDS

Inspection, measuring, examining and testing: We are continuously
improving our products and manufacturing processes. Targeted prod-
uct and process enhancement is based on qualitative and quantitative
evaluation of all relevant facts and parameters. For this purpose all
common examination methods are applied in-house by our qualified
and trained staff. For technically more complex processes or those
used less frequently (such as quenching dilatomery, radiography or
creep rupture) we work together in close cooperation with universities
and research organisations.

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Always good
Quality does not happen on its own but is the result of planned
working sequences and the special sense of responsibility shared
by our employees. Smart resource management and a constant
dialogue with the employees generate a transparent quality policy
and reproducible processes. High-quality products are the result
of all components in a process chain being handled diligently and
self-evidently.
Consultancy
People do the business. People are the key to success. Therefore,
personal consulting before, during and after joint projects is a core of
our work. You can rely on our know-how.
Shared skills transfer
For continuous improvement our employees regularly participate
in conferences in Germany and abroad. Furthermore, involvement
in various committees and industry associations strengthens our
competence and market knowledge. We are pleased to share our
know-how with you – at training sessions and presentations on your
or our premises.
Research and development
The central materials engineering department is where all the R&D
activities for all business divisions come together. We are currently
working on approx. 30 projects, often in cooperation with external
research organisations.
Our R&D subjects emerge directly from market requirements. Further
approaches for the development of innovative solutions are gained by
a holistic material analysis, ranging from metallurgy to heat treatment
to surface technique.
Documented quality
Certifications (such as DIN EN ISO 9001:2000) are the visible
expression of our quality standards. High customer satisfaction,
partnership relationships and compliance with standards are the basis
for long-term customer and supplier relationships.
More than just steel
We support our partners wherever we can. In close collabora-
tion with customers we define how support can be extended
beyond the mere product.
ƒ Research ƒ Materials testing
ƒ Studies ƒ Analyses/reports
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HOW TO FIND US
SPECIAlƒSTEEl
ƒ Cold work steel
ƒ Hot work steel
ƒ High-speed steel
ƒ Plastic mould steel
ƒ Powder-metallurgical steel
ƒ Stainless steels
ƒ Nitriding steels
ƒ Tempered steel
ƒ Precision flat steel
ƒ Special grades
Weiershagen plant
Weiershagener Str. 80
51674 Wiehl
Germany
Dörrenberg Edelstahl GmbH
Postfach 21 64
51758 Engelskirchen
Germany
Tel.: +49 2263 79 0
Fax: +49 2263 79 430
E-Mail: formguss@doerrenberg.de
www.doerrenberg.de
SPECIAL STEEL CASTINGS INvESTmENTƒCASTINgS
ƒ Global procurement of cast
products and drawing-
specific metal components
ƒ Materials and design
engineering consultancy
ƒ CAD data exchange
ƒ Solidification simulation
ƒ Rapid prototyping,
rapid tooling
ƒ Mechanical machining
ƒ Range of different surface
finishing processes
Ründeroth plant Dieringhausen plant
Hammerweg 7 Stahlstr. 6
51766 Engelskirchen 51645 Gummersbach
Germany Germany
SurFACEƒTrEATmENT
ƒ Heat treatment
ƒ Induction hardening
ƒ Polishing of tools and
components
ƒ Plasma nitriding
ƒ NOX® coatings
ƒ Hard material coatings
using the CVD, PVD and
PA-CVD method
ƒ Coating removal and
re-coating
ƒ Treatment (coating and
polishing) of complete tools,
incl. removal and fitting
Ründeroth plant
Hammerweg 7
51766 Engelskirchen
Germany