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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. $$$

South Gate, CA  |  562-928-1387

At Pacific Alloy, we are a one-stop source for casting design assistance, pattern construction, casting production and finish machining. Ever since our inception nearly 80 years ago, we have served a multitude of industries including agriculture, mining, and construction. Call or visit our website today and ask us what we can do for you.

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Pacific Alloy Castings Co., Inc. $$$

Galena, IL  |  815-777-0242

For over a century Lemfco has been a family business and leading manufacturer of high-quality grey iron castings. We pride ourselves on our extensive list of products and patterns available for our customers. Lemfco is committed to creating the best gray iron castings for our customers to fit all of their needs. Our company has changed throughout the years, but our commitment to quality never has.

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Lemfco, 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. $$$

Corsicana, TX  |  903-872-6571

Oil City Iron Works, Inc. is a jobbing shop foundry in Texas specializing in Gray and Ductile Iron Castings, with a large CNC Machine Shop, modern Pattern Shop, Heat Treatment Furnaces and a Surface Coating facility. Since 1866, we have continued to expand the diversity of our products and are dedicated to quality with our ISO 9001:2015 Certification. We guarantee that you will come away satisfied with the work we have done, since our Customers are our number one priority! How can we serve you today?

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Oil City Iron Works $$$

Huntington Beach, CA  |  714-962-1064

With over 50 years in cast iron metalworking, you can trust Mesa Castings’ expertise in grey iron, white iron, nickel-chromium alloyed & high chromium alloyed castings. The finest ductile and abrasion resistant iron castings individually engineered using the latest technology, exceeding ASTM, ASME & SAE. We combine over 100 years of experience with the finest materials to produce high quality.

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Mesa Castings, Inc. $$$
placeholder image Modern Aluminum Castings Co., Inc. Pacific Alloy Castings Co., Inc. Lemfco, Inc. Impro Industries USA, Inc. Oil City Iron Works Mesa Castings, Inc.

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.

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