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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

Webster City, IA  |  515-832-1722

Seneca Foundry is a manufacturer of gray and ductile iron castings, ranging in size from ounces to 250 pounds. Our customer base is from a wide range of industries, such as agriculture, industrial, cookware and more. We offer a variety of molding processes including green sand, lost foam, and no-bake. Our versatility enables us to give the customer the best solution for their casting needs. Contact us today to get started!

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Seneca Foundry, Inc. $$$

Waukesha, WI  |  800-544-4800

American Iron & Alloys Corporation is a leading manufacturer of gray iron castings and ductile iron castings. Our Versa-Bar® brand of castings comes in various sizes and shapes and can be custom cast. We provide a wide variety of industries with quality cost-efficient castings.

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American Iron & Alloys Corporation $$$

Clarksville, TN  |  931-647-1538

Clarksville Foundry specializes in manufacturing short-run, top-quality castings using a range of materials. Some of our casting capabilities include ductile iron castings and alloy castings. With over 150 years of experience, expect nothing but high-quality products and outstanding service.

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Clarksville 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. $$$

Salem, OH  |  330-332-1566

In need of alloy castings, carbon steel castings, ductile iron castings or gray iron castings? We invite you to use our ISO 9001:2000-certified company. Thus far, we have produced product for many industries: agricultural; bridge and crane; drilling and mining; fittings; glass; tool and die; tire; valves.

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Quaker City Castings, Inc. $$$

New Liskeard, ON  |  705-647-4383

Wabi leads the industry in manufacturing loading and conveying systems, and general and abrasion-resistant castings to satisfy industrial and OEM requirements. Our company has an on-site fabrication facility, foundry and machine shop, which enables us to have control over the entire manufacturing process so we ship products of the highest quality. To learn more about our capabilities, contact Wabi today!

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Wabi Iron & Steel Corp. $$$
placeholder image Seneca Foundry, Inc. American Iron & Alloys Corporation Clarksville Foundry, Inc. Impro Industries USA, Inc. Quaker City Castings, Inc. Wabi Iron & Steel Corp.

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