TDC Alloys is an ISO 9001:2015 certified, industry-leading Gear & Pinion Casting Manufacturer in India, delivering high-integrity cast steel gear and drive pinion sets for heavy mechanical power transmission. The gear wheel and its driving pinion form the foundational torque-multiplying core of heavy industrial machinery, demanding tight metallurgical compatibility, uniform grain structure, and high tooth root bending strength. Our Gear & Pinion Casting in India uses 3D solidification mold-flow modeling, electric induction melting, and high-density sand molding to manufacture castings engineered for zero internal porosity and maximum fatigue life.
From rotary kiln girth gear wheels and high-torque mill drive pinions to heavy spur, helical, and double-helical reduction gear sets, TDC Alloys manufactures components from 10 kg up to 3,000 kg per piece. We pour high-strength alloy steels (ASTM A148 Gr. 90-60, 105-85, 120-95), chrome-moly steels (42CrMo4, En19), Ni-Cr-Mo steels (34CrNiMo6, En24), and carbon steels (IS 1030). All gear and pinion castings undergo 100% volumetric Ultrasonic Testing (UT) across the rim and roots to guarantee flawless gear cutting across India.
Matched Gear & Pinion Set
High-Torque Mill Pinion
Kiln Girth Gear Casting
As a specialized Gear & Pinion Casting Manufacturer in India, TDC Alloys matches metallurgy between mating gear and pinion pairs:
High core strength and hardenability for drive pinions undergoing higher cycle fatigue than mating gears, responsive to tooth induction hardening.
Nickel-Chrome-Moly alloys designed for heavy shock loads in ball mill and crusher drive pinions, maintaining high notch impact toughness.
Selected with hardness differential (pinion typically 30-50 HB harder than gear wheel) to ensure balanced wear rates and long operational service life.
Normalized cast carbon steels delivering reliable weldability, vibration damping, and structural soundness for massive gear wheel rims and spokes.
Our programmable heat treatment regimens tailor the mechanical properties of each alloy heat to match exact operational service demands:
| Grade / Standard | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | Hardness (HB) | Primary Engineering Application |
|---|---|---|---|---|---|
| 42CrMo4 / En19 | 850 - 1050 | ≥ 650 | ≥ 12% | 280 - 340 HB | High-Torque Drive Pinions |
| 34CrNiMo6 / En24 | 900 - 1100 | ≥ 700 | ≥ 11% | 300 - 360 HB | Heavy Shock Load Mill Pinions |
| ASTM A148 Gr. 105-85 | 725 - 850 | ≥ 585 | ≥ 17% | 217 - 269 HB | Mating Bull Gears & Girth Gears |
| ASTM A148 Gr. 90-60 | 620 - 725 | ≥ 415 | ≥ 20% | 187 - 229 HB | Large Mating Gear Wheels |
| IS 1030 Gr. 280-520W | 520 - 640 | ≥ 280 | ≥ 22% | 150 - 190 HB | Large Low-Stress Gear Webs & Rims |
Demanding engineering sectors across India rely on TDC Alloys for metallurgical performance and dependable delivery:
Every Gear & Pinion Casting in India manufactured by TDC Alloys undergoes meticulous non-destructive and destructive examination:
Direct-reading optical emission spectrometer verifies 28+ chemical elements per heat to guarantee exact alloy compounding.
Computer-monitored furnaces carry out normalizing, liquid water/oil quenching, high-temperature tempering, and stress relieving.
Ultrasonic Testing (UT per ASTM A609), Magnetic Particle Inspection (MPI per ASTM A275), Radiography (RT), and Dye Penetrant.
Full material test reports with mechanical, chemical, heat treatment, Charpy impact down to -46°C, and TPI sign-offs.
Leading industrial enterprises and engineering OEMs in India partner with TDC Alloys for our technical capabilities and commitment to quality:
Mating gears and pinions need a controlled hardness differential (the smaller pinion experiences many more stress cycles and must be slightly harder) to ensure even wear and prevent tooth galling.
We produce single-piece castings from 10 kg up to 3,000 kg and pitch diameters up to 3.5+ meters.
Yes. Our heat treatment facilities offer full normalizing, quenching & tempering, and specialized tooth profile induction hardening to achieve required root and flank hardness.
Every gear and pinion undergoes 100% volumetric Ultrasonic Testing (UT per ASTM A609) across the rim and roots, plus Magnetic Particle Testing (MPI) to guarantee zero subsurface defects.
Every shipment includes EN 10204 3.1 Material Test Certificates with 28-element optical spectrometry, mechanical tensile and Charpy impact tests, and NDT reports.
Submit your drawings, material specifications, and batch quantities for prompt technical review and direct foundry pricing.
