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Iron Foundries

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Iron Foundries Iron foundries are facilities that provide all of the services necessary to produce iron castings of various sizes and shapes. Although commonly used synonymously with forges, only a foundry manufactures closed mold iron castings.
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Leading Manufacturers

Terre Haute, IN  |  800-467-6252

Modern Aluminum Castings Co., Inc. has been a designer and manufacturer of aluminum and iron castings since 1919. Industries served include the sporting goods, medical devices, industrial machinery, HVAC, automotive, electrical lighting, appliance, and construction industries. Other services include forgings, stampings, custom machined components, and others.

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Modern Aluminum Castings Co., Inc. $$$

Chicoutimi, QC  |  418-545-8181

As an ISO 9001:2008 certified company our customers know that they are always going to receive the highest quality products and services available! Our research and development department works around the clock in order to ensure that our products remain on the leading edge of innovations at all times because we realize that our customers rely on the most advanced grey iron castings. Visit our website today!

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Saguenay Foundry $$$

Benton, PA  |  570-925-6711

For nearly a century, Benton Foundry has been supplying iron castings to a variety of industries, building a reputation for consistent, high-quality castings delivered on time. Working with all types of gray iron and ductile iron, Benton provides quality components and extraordinary service at a low net cost. Put Benton’s near 100 year history to work for your most challenging casting application.

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Benton Foundry, Inc. $$$

Diamond Bar, CA  |  877-484-6776

Impro Industries is globally recognized as a leading provider of high-precision, high-complexity, and mission-critical casting and machined components. Industries served include automotive, aerospace, medical, and many mor. Our team is dedicated to the quality of our every project, ensuring the highest customer satisfaction. Contact us today to learn more about our grey iron casting capabilities.

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Impro Industries USA, Inc. $$$

Cedar Grove, WI  |  920-668-8526

Willman stands for quality grey iron castings that you can count on for many years to come. As a leading manufacturer producing all types of precision components, weighing from ounces to 40,000 lbs, Willman can satisfy your demands for complex engineering solutions. Willman employs skilled workers & the most advanced equipment for economical production, giving you the quality assurance you want.

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Willman Industries, Inc. $$$

Ashland, PA  |  570-875-6100

Ashland Foundry & Machine Works LLC (AFMW) is a world class manufacturer of grey iron castings. We have the ability to produce castings from a few pounds to 10,000 lbs in steel and 17,000 lbs in iron grades. We utilize 7 coreless induction furnaces ranging in size from 500 lbs. to 7,500 lbs. In addition to machining, we offer hydro testing, impeller balancing and polishing. We are ISO 9001:2015 certified.

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Ashland Foundry and Machine Works $$$
placeholder image Modern Aluminum Castings Co., Inc. Saguenay Foundry Benton Foundry, Inc. Impro Industries USA, Inc. Willman Industries, Inc. Ashland Foundry and Machine Works

To accomplish the iron casting process, foundries posses the equipment and supplies required to analyze and mix raw materials before heating them to extreme temperatures in order to liquefy them. The molten cast iron is then poured into molds that may be manufactured at the foundry or produced elsewhere depending on the capabilities of a specific facility.

Once filled the mold and material it houses must be cooled to solidify the part. While some iron foundries allow the casts to cool at room temperature, other operations require advanced cooling technology. These factories often require a great deal of both floor and storage space to house equipment, finished parts and pre-production materials.

Gray and Ductile Iron Casting Iron Foundries - Knapp Foundry Company

While some process several metals rather than just iron, it is often beneficial to have a specialty in order to stay relevant within the highly competitive field of metallurgy. Iron foundries draw business from such versatile industries as automotive, agriculture, water and sewage treatment, irrigation, ventilation, hydraulics, manufacturing, machinery building, electronics, transportation, construction and building.

The processes undertaken at an iron foundry begin with a selection of materials. The proper elemental and chemical composition is produced during the melting stage of casting. A specialized blast furnace known as a cupola is used to achieve the temperatures necessary to melt iron and additives such as scrap steel and iron. The high heat also refines the melt which is then poured into a mold by hand or automatically.

Any number of casts can be made and housed at a given foundry for continuous or one time use. These molds are solid or split pattern, meaning composed of one or two pieces. The latter have a top portion known as a cope and a lower section called a drag. Molds may also have core processes for the creation of parts and products with cavities or reentrant angles. Pouring may be use gravity, a vacuum or pressurized gas to completely fill the mold which is then allowed to cool.

Cooling is carefully controlled to encourage the development of the internal microstructure of a cast part or component. A fully cooled cast iron piece is then ejected from the mold. As casting often leaves burrs or other artifacts, most foundries offer surface cleaning and finishing processes such as grinding, sanding and machining.

Secondary operations such as painting, galvanizing, heat treating and assembly may also be available at an iron foundry. The capabilities of a specific facility should be considered with regards for production needs.

Iron Foundries Informational Video

 

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