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.

Leading Manufacturers

Florence, AL  |  256-766-8720

Our gray iron castings are second to none. These high performance items are pre-tested for maximum customer satisfaction. We have a component staff that can easily handle your requests. Turn to Interstate Castings for the best gray iron castings. You will not be upset with the quality of items you receive. We look forward to working with your business. Give us a call today!

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Imperial Casting Company, Inc. $$$

West Salisbury, PA  |  814-662-2809

West Salisbury Foundry & Machine specializes in gray iron castings, alloy castings, ductile iron castings, white iron castings & ni-hard castings. Since 1884, we have served diverse markets such as printing, railroad, foundry equipment, steel mill, electrical, electrical, mining, the stoker industry & others. We serve industries such as pumps, compressors, machine tool, oil field equipment & more.

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West Salisbury Foundry and Machine Company $$$

Fontana, CA  |  909-428-0114

Commercial Casting specializes in gray iron castings and ductile iron castings. We provide top-quality castings for a wide range of industries, including aerospace, tool and die, construction, gas compression, machine tool, power generation, ship building, specialty equipment and water pumping.

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Commercial Casting Company $$$

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. $$$

Manheim, PA  |  717-898-2210

Since 1980, Bearon has been a top provider of grey iron castings and other components. Bearon components are crafted from aluminum, brass, bronze, cast iron, ductile iron and malleable iron to suit a range of industrial applications. With manufacturing capabilities including casting, machining, fabrication, finishing, molding and more, Bearon can take care of your projects from start to finish.

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Bearon Manufacturing, LLC $$$
placeholder image Imperial Casting Company, Inc. West Salisbury Foundry and Machine Company Commercial Casting Company O.K. Foundry Company, Inc. Bearon Manufacturing, LLC

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