--- title: "From Historic Tank Track to Functional Casting: Phenix Foundry Supports a Restoration Project" description: We recently produced a gray iron cast gear component for an industrial customer. The design balanced integrated drive teeth, four cast holes, and weight... image: https://www.phenixfoundry.com/hubfs/blog/Ductile%20Iron%20Castings%20-%20Tank%20Tracks%20Restoration%20Project-1.jpg --- [Skip to the main content.](https://www.phenixfoundry.com/news-and-events/from-historic-tank-track-to-functional-casting-phenix-foundry-supports-a-restoration-project#main-content) - [334-298-0441](tel:3342980441) - [Request a Quote](https://www.phenixfoundry.com/contact-us) [![Phenix Foundry - ductile iron castings and gray iron castings specialist - 2](https://www.phenixfoundry.com/hs-fs/hubfs/Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png?width=380&height=151&name=Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png "Phenix Foundry - ductile iron castings and gray iron castings specialist - 2")](https://www.phenixfoundry.com) [![Phenix Foundry - ductile iron castings and gray iron castings specialist - 2](https://www.phenixfoundry.com/hs-fs/hubfs/Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png?width=378&height=150&name=Phenix%20Foundry%20-%20ductile%20iron%20castings%20and%20gray%20iron%20castings%20specialist%20-%202.png "Phenix Foundry - ductile iron castings and gray iron castings specialist - 2")](https://www.phenixfoundry.com) - [Gray Iron Casting](https://www.phenixfoundry.com/gray-iron-castings) - [Ductile Iron Casting](https://www.phenixfoundry.com/ductile-iron-castings) - [Capabilities & Services](https://www.phenixfoundry.com/capabilities-services) - [Machining](https://www.phenixfoundry.com/machining) - [Paint & Coating](https://www.phenixfoundry.com/paint-coatings) - [Weldment Conversion](https://www.phenixfoundry.com/weldment-conversion) - [Our Equipment](https://www.phenixfoundry.com/our-equipment) - [About](https://www.phenixfoundry.com/about) - [About Us](https://www.phenixfoundry.com/about) - [History](https://www.phenixfoundry.com/history) - [Our Process](https://www.phenixfoundry.com/our-iron-casting-process) - [Green Sand Molding](https://www.phenixfoundry.com/green-sand-molding) - [Brochure](https://www.phenixfoundry.com/brochure-download) - [News & Events](https://www.phenixfoundry.com/news-and-events) - [Contact](https://www.phenixfoundry.com/contact-us) Toggle Menu Toggle Menu - [Gray Iron Casting](https://www.phenixfoundry.com/gray-iron-castings) - [Ductile Iron Casting](https://www.phenixfoundry.com/ductile-iron-castings) - [Capabilities & Services](https://www.phenixfoundry.com/capabilities-services) - [Machining](https://www.phenixfoundry.com/machining) - [Paint & Coating](https://www.phenixfoundry.com/paint-coatings) - [Weldment Conversion](https://www.phenixfoundry.com/weldment-conversion) - [Our Equipment](https://www.phenixfoundry.com/our-equipment) - [About](https://www.phenixfoundry.com/about) - [About Us](https://www.phenixfoundry.com/about) - [History](https://www.phenixfoundry.com/history) - [Our Process](https://www.phenixfoundry.com/our-iron-casting-process) - [Green Sand Molding](https://www.phenixfoundry.com/green-sand-molding) - [Brochure](https://www.phenixfoundry.com/brochure-download) - [News & Events](https://www.phenixfoundry.com/news-and-events) - [Contact](https://www.phenixfoundry.com/contact-us) 2 min read # From Historic Tank Track to Functional Casting: Phenix Foundry Supports a Restoration Project [Michael Smith](https://www.phenixfoundry.com/news-and-events/author/michael-smith) : Updated on November 1, 2026 [ductile iron castings](https://www.phenixfoundry.com/news-and-events/tag/ductile-iron-castings) [iron casting production](https://www.phenixfoundry.com/news-and-events/tag/iron-casting-production) ![From Historic Tank Track to Functional Casting: Phenix Foundry Supports a Restoration Project](https://www.phenixfoundry.com/hubfs/blog/Ductile%20Iron%20Castings%20-%20Tank%20Tracks%20Restoration%20Project-1.jpg) ![1 Ductile Iron Castings - Restoration Project - Tank\_1](https://www.phenixfoundry.com/hs-fs/hubfs/blog/1%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank_1.jpg?width=420&height=280&name=1%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank_1.jpg) Phenix Foundry was recently selected by the [National Armor and Cavalry Heritage Foundation (NACHF)](https://armorcavalryheritagefoundation.org/) to hel p recreate track components for a German WWII Sturmgeschütz IV, an assault gun variant of the Panzer IV tank. The NACHF houses the largest collection of U.S. armored vehicles and the second-largest armored vehicle collection in the world. The challenge was to reproduce a complex original cast-steel track link using a design suited to modern fo undry production, while maintaining the geometry and functional requirements needed for the vehicle’s restoration. **Engineering a More Manufacturable Design** The original track link incorporated parallel links, hollow guide fins and hollow clearances for ice and stone removal. Each link had to nest with adjacent links, connect through pins on both sides, engage a 20-tooth front sprocket and align with a series of guide wheels. ![2 Ductile Iron Castings - Restoration Project - Tank Tracks\_2](https://www.phenixfoundry.com/hs-fs/hubfs/blog/2%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank%20Tracks_2.jpg?width=420&height=280&name=2%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank%20Tracks_2.jpg) Recreating the component required careful consideration of parting lines, green sand mold partings, core design, pockets and draft angles—all critical to producing a complex casting. ([See our design guidel for casting manufacturability here.](https://www.phenixfoundry.com/engineering-guide-for-iron-castings)) Phenix began by working with the customer to establish the component’s intended use and strength requirements, identify opportunities to simplify the geometry for manufacturability, confirm identification markings, determine any machining or fitting requirements, and establish the required quantity. Choosing Ductile Iron for Strength & Durability ![3 Ductile Iron Castings - Restoration Project - Tank Tracks](https://www.phenixfoundry.com/hs-fs/hubfs/3%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank%20Tracks.jpg?width=420&height=280&name=3%20Ductile%20Iron%20Castings%20-%20Restoration%20Project%20-%20Tank%20Tracks.jpg)Based on these discussions, the team selected [ductile iron](https://www.phenixfoundry.com/ductile-iron-castings) for the recreated component. Characterized by its strength, toughness and impact resistance, ductile iron offers the durability needed to withstand demanding service conditions, including the repeated loads and mechanical stresses experienced by tank tracks. The revised geometry eliminated the body core while retaining a cored passage for the connecting links. This passage was formed using a core (a shaped insert used to create internal openings in a casting), eliminating the need for further machining and allowing a standard cold-rolled rod to serve as the connecting pin rather than reproducing the original metric-sized pin. **From Model to Production** ![4 Ductile Iron Castings - Model with Cast-in Identification - casting ID](https://www.phenixfoundry.com/hs-fs/hubfs/blog/4%20Ductile%20Iron%20Castings%20-%20%20Model%20with%20Cast-in%20Identification%20-%20casting%20ID.jpg?width=400&height=267&name=4%20Ductile%20Iron%20Castings%20-%20%20Model%20with%20Cast-in%20Identification%20-%20casting%20ID.jpg)The shape was hand-modeled for approval, after which the mathematical model was created. To support the required production quantity, tooling was manufactured from billet aluminum, along with an iron shell core box incorporating two unique core shapes. The tooling was molded on a 16 × 20 Blo-Matic matchplate, a pattern plate used to form the mold. Initial castings were produced and submitted to the customer for review. Following acceptance of the first-off samples, production began to support the restoration project. **A Casting with a History** The original track’s cast-in identification also carried historical significance. The “BYR” marking identifies Ruhrstahl AG, Annener Guss-stahlwerk, in Witten-Annen, Germany.  ![5 Ductile Iron Castings - Approved Image is Hand Modeled - 2](https://www.phenixfoundry.com/hubfs/5%20Ductile%20Iron%20Castings%20-%20Approved%20Image%20is%20Hand%20Modeled%20-%202.jpg) ![5 Ductile Iron Castings - Approved Image is Hand Modeled - 1-1](https://www.phenixfoundry.com/hubfs/blog/5%20Ductile%20Iron%20Castings%20-%20Approved%20Image%20is%20Hand%20Modeled%20-%201-1.jpg) Cast-in identification is created during the molding process, rather than added to the finished casting through stamping, engraving or other marking methods. The lettering or identification details are incorporated into the pattern or mold so that, when molten metal fills the mold, the markings become an integral part of the casting itself. This allows foundry names, identification codes and other information to remain permanently identifiable as part of the component. The Annener cast steelworks were an important part of Germany’s wartime industrial operations, where forced labor was used to meet the demands of weapons production. Estimates indicate that approximately 25,000 forced laborers from occupied territories were part of the workforce. ![7 - Ductile Iron Casting with Cast In Identification - 2](https://www.phenixfoundry.com/hubfs/blog/7%20-%20Ductile%20Iron%20Casting%20with%20Cast%20In%20Identification%20-%202.jpg) ![7 - Ductile Iron Casting with Cast In Identification - 1](https://www.phenixfoundry.com/hubfs/blog/7%20-%20Ductile%20Iron%20Casting%20with%20Cast%20In%20Identification%20-%201.jpg) As foundrymen and women understand, operating a foundry requires considerable physical labor. The forced labor imposed on workers at these facilities adds a sobering dimension to the history behind this casting. The camp associated with the works was liberated on April 11, 1945, by the U.S. Army’s 75th Infantry Division. Holding this casting today, I am reminded of the people who held it before me and the history they endured. Phenix Foundry appreciates the opportunity to contribute its casting and engineering expertise to this restoration project and thanks Perfect Patterns South for its modeling and tooling support. Speak with one of our experts about your next project!  [Contact us.](https://www.phenixfoundry.com/contact-us) Download our FREE Guide: [*Engineering Drawings for Iron Castings*](https://www.phenixfoundry.com/engineering-guide-for-iron-castings) [*- Design Guidelines for Manufacturability*](https://www.phenixfoundry.com/engineering-guide-for-iron-castings) [![Phenix\_Engineering Design Guide for Iron Castings\_](https://www.phenixfoundry.com/hs-fs/hubfs/CTAs/Phenix_Engineering%20Design%20Guide%20for%20Iron%20Castings_.png?width=369&height=311&name=Phenix_Engineering%20Design%20Guide%20for%20Iron%20Castings_.png)](https://www.phenixfoundry.com/engineering-guide-for-iron-castings) [![Download Now](https://hubspot-no-cache-na2-prod.s3.amazonaws.com/cta/default/245288987/interactive-420264413939.png)](https://www.phenixfoundry.com/hs/cta/wi/redirect?encryptedPayload=AVxigLLHgHwjtrSneWI9Vl7iwvIl%2BZ2mPfdvSr9bq4mZetKLjdCsxPEhej72ksWqMrVc66MLKXM%2BrjeEiYfWl95mMsfUMMvKKEo4HXGNUMO6p6Nb02QOQPLhqvSnKv4FiFHXPXCKYgDMKb24p49ROLNZhAl%2BXp6kxwTndRJYHoXXyPgebzveNS8s%2FnIhTdNGk%2FbMcFzhowUxUcFXO7qZhW28FXx8GB8iWGq1xwPNXlJf6hsKNG9Vin57aQkT&webInteractiveContentId=420264413939&portalId=245288987)   [![Impeller Gray Iron Casting with Industrial Paint Finish](https://www.phenixfoundry.com/hubfs/Grey%20Iron%20Castings/Impeller%20-%20Gray%20Iron%20Casting%20-%20Machining%20-%20Paint%20Coating.jpg)](https://www.phenixfoundry.com/news-and-events/impeller-gray-iron-casting-with-industrial-paint-finish) 1 min read #### [Impeller Gray Iron Casting with Industrial Paint Finish](https://www.phenixfoundry.com/news-and-events/impeller-gray-iron-casting-with-industrial-paint-finish) [Admin](https://www.phenixfoundry.com/news-and-events/author/admin) : Oct 14, 2026, 8:00:00 AM Phenix Foundry recently produced a gray iron industrial impeller with machining, surface preparation, and a finished paint coating, providing our... [ductile iron castings](https://www.phenixfoundry.com/news-and-events/tag/ductile-iron-castings) [iron casting production](https://www.phenixfoundry.com/news-and-events/tag/iron-casting-production) [Read More](https://www.phenixfoundry.com/news-and-events/impeller-gray-iron-casting-with-industrial-paint-finish) [![Gray Iron Gear Component](https://www.phenixfoundry.com/hubfs/blog/gray%20iron%20casting%20-%20gear%20component%20_1.jpg)](https://www.phenixfoundry.com/news-and-events/gray-iron-gear-component) 1 min read #### [Gray Iron Gear Component](https://www.phenixfoundry.com/news-and-events/gray-iron-gear-component) [Admin](https://www.phenixfoundry.com/news-and-events/author/admin) : Jul 31, 2026, 9:00:00 AM Phenix Foundry recently produced a gray iron cast gear component for an industrial customer, manufactured through a repeatable green sand casting... [ductile iron castings](https://www.phenixfoundry.com/news-and-events/tag/ductile-iron-castings) [iron casting production](https://www.phenixfoundry.com/news-and-events/tag/iron-casting-production) [Read More](https://www.phenixfoundry.com/news-and-events/gray-iron-gear-component) [![From Weldment to Casting: How Phenix Foundry Helped Streamline Oil Rig Stabbing Guide Production](https://www.phenixfoundry.com/hubfs/blog/Oil%20Rig%20Stabbing%20Guide%20-%20Weldment-to-Casting%20Conversion.jpg)](https://www.phenixfoundry.com/news-and-events/from-weldment-to-casting-how-phenix-foundry-helped-streamline-oil-rig-stabbing-guide-production) 3 min read #### [From Weldment to Casting: How Phenix Foundry Helped Streamline Oil Rig Stabbing Guide Production](https://www.phenixfoundry.com/news-and-events/from-weldment-to-casting-how-phenix-foundry-helped-streamline-oil-rig-stabbing-guide-production) [Admin](https://www.phenixfoundry.com/news-and-events/author/admin) : Aug 7, 2026, 9:00:00 AM As offshore oil and gas infrastructure ages, replacing and improving critical components has become an important strategy for extending asset life.... 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