A foundry is defined as an establishment where metal is melted and poured into molds. Today, the most common metals processed are aluminum and cast iron. However, other metals, such as steel, magnesium, copper, tin, and zinc, are also used frequently.
Prior to pouring a metal casting, the foundry produces a pattern and mold. The mold represents the shape of the desired part. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. These mold processes commonly include: Sand Casting (green or resin bonded sand mold); Investment (Lost Wax) Casting - Wax or similar pattern with a ceramic mold; Plaster Casting - Plaster mold; and Die Casting - Metal mold.
Prior to pouring a metal casting, the foundry produces a pattern and mold. The mold represents the shape of the desired part. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. These mold processes commonly include: Sand Casting (green or resin bonded sand mold); Investment (Lost Wax) Casting - Wax or similar pattern with a ceramic mold; Plaster Casting - Plaster mold; and Die Casting - Metal mold.
In a foundry, molten metal is poured into molds to take the shape of the cavity left by the pattern. The solidified metal component is then removed from its mold. The mold is destroyed, but can be recycled through a reclamation system. At this point, the cast component is still attached to the metal runners and gates - which are the channels through which the molten metal travelled to reach the component itself.
Runners and gates are cut from the component and re-melted for future use. The final step in the process usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape and surface finish. After grinding, any surfaces that requires tight dimensional control are machined.
Runners and gates are cut from the component and re-melted for future use. The final step in the process usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape and surface finish. After grinding, any surfaces that requires tight dimensional control are machined.