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Seaworthy by Design: High-Stability
Castings for Marine Equipment

KBR engineer corrosion-resistant, high-strength castings for marine structures—from engine bases to equipment housings. Built to withstand harsh maritime environments, our components ensure lasting stability and precision where it matters most.

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Challenges

The High-Performance Demands of Structural Components for Marine Equipment

Marine equipment operates in harsh and demanding ocean environments, where reliability directly determines navigational safety and mission success. Structural components for maritime applications are not merely supporting frameworks; they form the essential foundation for overall system stability and durability. Any compromise in structural strength, corrosion resistance, or dimensional precision can lead to increased equipment failure rates, higher maintenance costs, and risks of operational disruption.

Vibration Damping & Structural Stability

Under dynamic marine conditions, ship vibrations and rolling motions are directly transmitted to equipment structures. Even slight resonance or structural deformation may cause misalignment, wear, or performance degradation in critical systems such as propulsion units and detection equipment. Marine structural castings must provide excellent vibration absorption and impact resistance to ensure reliable operation under sustained dynamic loading.

Corrosion Resistance & Structural Integrity

Marine equipment operates long-term in environments characterized by high salinity, high humidity, and significant temperature variations, placing stringent demands on material corrosion resistance and structural soundness. Structural castings must be made from highly corrosion-resistant alloys, with strict control over casting defects such as porosity and inclusions, to prevent corrosion propagation, fatigue crack growth, and structural failure—ensuring long-term service safety in demanding marine conditions.

Structural Rigidity & Fatigue Resistance

During navigation and operations, vessels are subjected to multiple forces including wave impact, equipment loads, and their own weight. Structural components must possess high static and dynamic rigidity to resist deformation and maintain precise alignment between systems. Moreover, fatigue resistance under long-term cyclic loading is critical to preventing fracture and failure throughout the equipment's service life, directly impacting vessel maneuverability, mission continuity, and maintenance intervals.

Process

KBR Marine Solution Matrix

Marine Equipment Challenges	Required Material Properties	KBR's Verifiable Solutions & Evidence
Suppressing structural vibrations in dynamic marine environments	Excellent vibration damping and high impact resistance	High-grade gray cast iron (HT300-HT350) and special damping alloys: Materials with superior vibration attenuation and impact energy absorption characteristics, suitable for marine power bases and critical load-bearing structures.
Resisting seawater corrosion and biofouling environments	High corrosion resistance, pitting resistance, and low porosity	Marine corrosion-resistant alloy cast iron and nickel-aluminum bronze materials: Special alloy formulations and surface treatment processes ensure long-term structural integrity in salt spray, high-temperature, high-humidity, and marine biological environments.
Ensuring long-term service stability of large hull structural components	Low residual stress, fatigue resistance, and high dimensional stability	Ultra-large integrated sand casting and stress relief processes: Capable of producing marine structural components weighing over 15,000 kg. Multi-stage heat treatment processes control internal stresses to ensure dimensional stability under long-term alternating loads.
Meeting precision installation and alignment requirements for marine equipment	High dimensional accuracy and complex surface machining capabilities	Five-axis gantry machining and full-size 3D inspection: Equipped with large five-axis gantry milling machines, achieving ±0.1mm accuracy for key components such as marine propeller bases and steering gear platforms, with installation matching verification via laser scanning.
Ensuring lifecycle quality traceability and maritime safety compliance	Classification society certification systems and full-process material testing	Hold factory approvals from classification societies such as CCS and DNV, with supporting metallographic, corrosion, fatigue, and non-destructive testing laboratories: Provide material certification reports compliant with international ship regulations and lifetime quality traceability records.

Quality Control

Qualification Through Verification:
Our Commitment to Quality

In high-stakes manufacturing, trust is earned through proof. Our quality system is not just a certificate on the wall; it is an integrated, data-driven process designed to mitigate risk and ensure absolute conformance to your specifications.Our entire operation is certified to the ISO 9001:2015 standard, ensuring a systematic, repeatable, and documented approach to quality assurance.

Quality Control

Comprehensive In-House
Metrology & Testing

We validate every critical parameter in our dedicated quality lab, providing you with complete transparency and verifiable data.

Spectrometer

To verify the precise chemical composition of every melt, ensuring material properties meet specifications like HT300 or QT450-15.

Tensile Strength & Hardness Testers

To confirm that the final casting possesses the required mechanical properties for strength, durability, and wear resistance.

Ultrasonic Flaw Detector

To perform ultrasonic inspection for castings. This ultrasonic flaw detection inspects the internal structure for subsurface porosity or inclusions, a critical step to prevent outgassing in vacuum components.

Metallographic Microscope

To examine the material's microstructure (e.g., graphite flake size in gray iron or nodularity in ductile iron), which dictates its performance characteristics.

3D Scanner

To perform 3D scanning for castings. This CAD-to-part inspection provides high-precision dimensional verification against the original CAD model, ensuring accuracy and conformance.

Projects

Typical Components forHigh-Performance Equipment

Shell casting component:
Shell castings with no excess material and zero porosity

Process:Coated Sand Process

Material: HT250 Gray Iron

Weight: 120 kg

The high-precision requirements for both the shell's exterior and interior can be perfectly achieved with the precoated sand process.

Pump diversion casting component:
High-Strength Structural Connectors

Process:Coated Sand Process

Material:QT450 Ductile Iron

Weight: 25kg

Coated sand process delivers ultra-smooth flow channels and surface finish.

Capabilities

Mastering the Craft : Our Dual Casting Processes

Request Casting Process Solution

Resin Sand Process

Coated Sand Process

Resin Sand Process

For Large-Scale & Heavy-Duty Castings

Our Resin Sand process is ideal for producing large, heavy, and structurally demanding castings. Using robust metal or wood patterns, High-strength sand shell, with a smaller draft angle,24 to 72 hours of insulation time.this process provides a cost-effective solution for low-to-medium volume production runs where structural integrity is paramount.

Key Specifications Table

Casting Weight: 50 kg – 10,000 kg

Best For: Low-to-medium volume (tens to hundreds annually)

Materials: Gray Iron (HT200,HT250,HT300,).Ductile Iron (QT400-QT450-QT500-QT600)

Applications: Machine Tool Bases, Large Housings, Construction Machinery Frames

Coated Sand Process

For High-Precision & High-Volume Components

When precision and surface finish are critical, our Coated Sand process delivers exceptional results. Using high-precision, long-life iron molds (100,000+ uses), By using the core shooter, we can produce more precise sand molds with a smaller draft angle.we achieve accuracy errors within 0.5mm, the surface roughness reaches Ra25.making it perfect for complex parts in high-volume production.

Key Specifications Table

Casting Weight: 5 kg – 1,000 kg

Best For: Hundreds to tens of thousands

Materials: Gray Iron (HT200,HT250,HT300,).Ductile Iron (QT400-QT450-QT500-QT600)

Applications: Valve, Cylinder block, Transmission parts

Trusted by Leading OEMs Worldwide for Gray & Ductile Iron Castings

Talk to us

Let's Build Your Next Great Component

Whether you have a complete CAD model or are in the early stages of design, we can provide expert guidance on material selection, process optimization, and design for manufacturability to ensure your project's success.

Discover Keboer

Seaworthy by Design: High-Stability Castings for Marine Equipment

Challenges

The High-Performance Demands of Structural Components for Marine Equipment

Vibration Damping & Structural Stability

Corrosion Resistance & Structural Integrity

Structural Rigidity & Fatigue Resistance

Process

KBR Marine Solution Matrix

Quality Control

Qualification Through Verification:Our Commitment to Quality

Quality Control

Comprehensive In-House Metrology & Testing

Spectrometer

Tensile Strength & Hardness Testers

Ultrasonic Flaw Detector

Metallographic Microscope

3D Scanner

Projects

Typical Components forHigh-Performance Equipment

Shell casting component:Shell castings with no excess material and zero porosity

The high-precision requirements for both the shell's exterior and interior can be perfectly achieved with the precoated sand process.

Pump diversion casting component:High-Strength Structural Connectors

Coated sand process delivers ultra-smooth flow channels and surface finish.

Capabilities

Mastering the Craft : Our Dual Casting Processes

Resin Sand Process

For Large-Scale & Heavy-Duty Castings

Key Specifications Table

Coated Sand Process

For High-Precision & High-Volume Components

Key Specifications Table

Trusted by Leading OEMs Worldwide for Gray & Ductile Iron Castings

Talk to us

Let's Build Your Next Great Component

Email

Phone / WhatsApp

Shanghai Office

Anhui Factory

Capabilities

VMC Casting Solutions

Application

About Keboer

Resource

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Seaworthy by Design: High-Stability
Castings for Marine Equipment

Qualification Through Verification:
Our Commitment to Quality

Comprehensive In-House
Metrology & Testing

Shell casting component:
Shell castings with no excess material and zero porosity

Pump diversion casting component:
High-Strength Structural Connectors