Foundry 2853363 223783004 2008-07-05T19:56:53Z William Grimes 605213 {{2otheruses|factories that make [[casting]]s of [[metal]]|foundries related to the [[electronics]] industry|foundry (electronics)}} [[Image:Clabecq JPG01.jpg|thumb|300px|Worker in a Foundry.]] A '''foundry''' is a [[factory]] which produces [[metal]] [[casting]]s from either [[ferrous]] or [[non-ferrous metals|non-ferrous]] alloys. Metals are turned into parts by melting the metal into a liquid, pouring the metal in a mold, and then removing the mold material or casting. The most common metal alloys produced are [[aluminum]] and [[cast iron]]. However, other metals, such as [[steel]], [[magnesium]], [[copper]], [[tin]], and [[zinc]], can be processed. The '''people''' who work in the foundry making molds and pouring castings traditionally worked moving sand extensively, and thus were affectionately called sandrats. ==Melting== Melting is performed in a [[furnace]]. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of the gates, risers, or defective castings. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. During the tap, final chemistry adjustments are made. ===Furnace=== {{main|furnace}} Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include [[electric arc furnace]]s (EAF), [[induction furnace]]s, [[Cupola (disambiguation)|cupolas]], [[Reverberatory furnace|reverberatory]], and crucible furnaces. Furnace choice is dependent on the alloy system and quantities produced. For ferrous materials, EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminum castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from mere ounces to hundreds of tons, and they are designed according to the type of metals that are to be melted. Also, furnaces must be designed around the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as [[zinc]] or [[tin]], melting furnaces may reach around 327 Celsius. Electricity, propane, or natural gas are usually used for these temperatures. For high melting point alloys such as steel or nickel based alloys, the furnace must be designed for temperatures over 3600 Celsius. The fuel used to reach these high temperatures can be electricity or [[Coke (fuel)|coke]]. The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for [[cast iron]]) may use a [[Cupola (disambiguation)|cupola]], induction furnace, or EAF, while a [[steel]] foundry will use an [[Electric arc furnace|EAF]] or [[induction furnace]]. [[Bronze]] or [[brass]] foundries use crucible furnaces or [[induction furnace]]s. Most [[aluminum]] foundries use either an electric resistance or gas heated [[crucible]] furnaces or reverberatory furnaces. ==Molding== [[Image:NNSX 41809 June 10 2008.JPG|thumb|right|222px|Northrop Grumman Newport News Foundry & Switch Engine.]] Prior to pouring a [[casting]], the foundry produces a mold. 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 include: * [[Sand casting|Sand Casting]] - Green or Resin bonded sand mold. * [[Lost-foam casting|Lost Foam Casting]] - Polystyrene pattern with a mixture of ceramic and sand mold. * [[Investment Casting|Investment (Lost Wax) Casting]] - Wax or similar sacrificial pattern with a ceramic mold * [[Shaw Process|Plaster Casting]] - Plaster mold * [[V-Process]] Casting - Vacuum is used in conjunction with thermoformed plastic to form sand molds. No moisture, clay or resin is needed for sand to retain shape. * [[Die casting|Die Casting]] - Metal mold. * [[Billet|Billet (Ingot) Casting]] - Simple mold for producing ingots of metal normally for use in other foundries. ==Pouring== [[Image:GearedLadle.png|thumb|right|222px|An old geared ladle]] In a foundry, molten metal is poured into [[Molding (process)|molds]]. Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines for pouring molten metal. Traditionally, molds were poured by hand using [[Ladle (metallurgy)|ladles]]. ==Shakeout== The solidified metal component is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the cast component, which will still be attached to the metal runners and gates - which are the channels through which the molten metal travelled to reach the component itself. ==Degating== Degating is the removal of the heads, runners, gates, and [[riser]]s from the casting. Runners, gates, and risers may be removed using [[cutting torch]]es, [[band saw]]s or ceramic cutoff blades. For some metal types, and with some gating system designs, the sprue, runners and gates can be removed by breaking them away from the casting with a hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required to produce castings in a mold yields leftover metal, including heads, risers and sprue, sometimes collectively called sprue, that can exceed 50% of the metal required to pour a full mold. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus melting costs. ==Surface Cleaning== After Degating, sand or other molding media may adhere to the casting. To remove this the surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The media strikes the casting surface at high velocity to dislodge the molding media (for example, sand) from the casting surface. Numerous materials may be used as media, including steel, iron, other metal alloys, aluminum oxides, glass beads, walnut shells, baking powder or numerous other materials. The blasting media is selected to develop the color and reflectance of the cast surface. Terms used to describe this process include cleaning, blasting, shotblasting and sand blasting of castings. ==Finishing== 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. Removing the remaining gate material, called a gate stub, is usually done using a [[Ginding machine|grinder]] or [[sanding]]. These processes are used because their material removal rates are slow enough to control the amount of material. These steps are done prior to any final machining. After grinding, any surfaces that requires tight dimensional control are machined. Many castings are machined in [[CNC]] [[Milling machine|milling]] centers. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for many components to be used without machining. A few foundries provide other services before shipping components to their customers. Painting components to prevent corrosion and improve visual appeal is common. Some foundries will assemble their castings into complete machines or sub-assemblies. Other foundries [[Welding|weld]] multiple castings or wrought metals together to form a finished product. ==Advantages== The finished product of a foundry can be more geometrically complex than the product of a [[Rolling (metalworking)|rolling]], [[forging]], or [[machining]] process like milling or turning. The mechanical properties of castings are equal in every direction, which makes them more suitable for multi-directional loading conditions. A foundry is the original way to produce [[near net shape]] parts. Castings frequently do not require or only require a little machining to create the finished part. ==References== *{{cite book | title = Foundry Technology | edition = 2nd edition | last = Beeley | first = Peter | authorlink = | publisher = [[Butterworth-Heinemann]] | location = [[Oxford, UK]] | year = [[2001]] | id = ISBN 978-0750645676 }} *{{cite book | title = Castings | edition = 2nd edition | last = Campbell | first = John | authorlink = John Campbell | publisher = [[Butterworth-Heinemann]] | location = [[Oxford, UK]] | year = [[2003]] | id = ISBN 978-0750647908 }} ==See also== * [[Coremaking]] ==External links== *[http://www.afsinc.org/ American Foundry Society] * NIOSH Safety Video: [http://www.cdc.gov/niosh/docs/video/found.html "Caution: Foundry at Work"] *[http://www.castsolutions.com/ Engineered Cast Solutions] *[http://www.fefinc.org/ Foundry Education Foundation] *[http://www.ctif.com/ Foundry Technical Center-France] *[http://www.moderncasting.com/ Modern Casting Magazine] *[http://www.stahlseite.de/fo2.htm Pictures of several foundries and big steel mills] *[http://www.sfsa.org/ Steel Founders' Society of America] *[http://www.afivic.com.au/ Australian Foundry Institute - Victoria] [[Category:Foundrymen]] [[Category:Metallurgy]] [[de:Giesserei]] [[fr:Fonderie]] [[lb:Géisserei]] [[simple:Foundry]] [[sr:Livenje]] [[sv:Hytta]]