Foundries

Foundries are industrial facilities that produce metal castings by melting metal and pouring it into molds. The solidified metal parts may form all or part of a finished component, and foundries differ from machine shops in their primary capability to produce complex shapes directly from molten metal.

Casting processes encompass a range of methods. Sand casting uses a sand-based mold and is widely used for a broad range of sizes and alloys. Investment casting employs ceramic investment molds for high accuracy and smooth finishes. Die casting injects molten metal under pressure into metal dies, suited to high-volume production of smaller parts. Shell molding uses a thin ceramic shell for better surface finish and dimensional control. Lost-foam and lost-wax techniques offer alternative mold forms. Metals used include ferrous alloys such as cast iron and steel, and non-ferrous alloys such as aluminum, zinc, copper, and magnesium. The choice of process depends on part geometry, required tolerances, surface finish, production rate, and cost.

Operations generally begin with melting in furnaces such as induction, cupola, or electric arc. A pattern or mold forms a cavity, sometimes with cores for internal features. Molten metal is poured, allowed to cool and solidify, then the part is removed from the mold (shakeout) and undergoes finishing steps, including gate and riser removal, heat treatment, machining, and surface finishing.

Quality control and safety are integral, with dimensional inspection, chemical analysis, and non-destructive testing to ensure compliance with standards. Environmental considerations include scrap recycling, waste management, emissions control, and energy use.