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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. $$$

Webster, SD  |  605-345-3349

Since 1977, Dakota Foundry has been a leader in the grey iron castings industry. Our expert team of leaders all have 25-30 years of experience and are ready to use their knowledge to help customers with their needs. Customers of Dakota Foundry can expect high-quality products and excellent service.

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Dakota Foundry $$$

Richmond, VA  |  804-233-9674

OK Foundry offers highly flexible gray and ductile iron castings. Family owned since 1912, we ensure tightly controlled metallurgy for production, prototype & one-of-a-kind engineering & architectural castings up to 700 lbs. Whether you need a handful of castings or regular shipments of large quantities, we offer shorter lead times & cheaper tooling. Your domestic partner for gray or ductile iron parts.

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O.K. Foundry Company, 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. $$$

Hanover, PA  |  717-632-4165

As a leading manufacturer of grey and ductile iron castings, Penn-Mar Castings has lead times as low as three weeks and the ability to pour castings ranging from 150 to 3,000 pounds. Our foundry uses a no-bake method to produce both complex cores as well as simple shapes. By determining the lowest scrap rate and reducing machining time, we offer long-term savings without compromising quality.

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Penn-Mar Castings, Inc. $$$

Maumee, OH  |  844-722-7846

For over 60 years, Carson Castings has been a leading manufacturer of grey iron castings. Through the years, we have built many relationships with our customers because they know we are reliable and responsive while creating high-quality products. Contact us today or visit our website for more information!

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Carson Castings $$$
placeholder image Modern Aluminum Castings Co., Inc. Dakota Foundry O.K. Foundry Company, Inc. Impro Industries USA, Inc. Penn-Mar Castings, Inc. Carson Castings

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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