Dictionary Definition
foundry n : factory where metal castings are
produced [syn: metalworks]
User Contributed Dictionary
English
Pronunciation
- , /faʊndɹi/, /faUndri:/
- Rhymes with: -aʊndɹi
Etymology
From fonderie.Noun
Related terms
Translations
Extensive Definition
A foundry is a factory which produces metal castings from either ferrous or 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
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 furnaces (EAF), induction furnaces, cupolas, 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.
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,
induction furnace, or EAF, while a steel foundry will use an EAF
or induction
furnace. Bronze or brass foundries use crucible
furnaces or induction
furnaces. Most aluminum foundries use either
an electric resistance or gas heated crucible furnaces or
reverberatory furnaces.
Molding
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 - Green or Resin bonded sand mold.
- Lost Foam Casting - Polystyrene pattern with a mixture of ceramic and sand mold.
- Investment (Lost Wax) Casting - Wax or similar sacrificial pattern with a ceramic mold
- 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 - Metal mold.
- Billet (Ingot) Casting - Simple mold for producing ingots of metal normally for use in other foundries.
Pouring
In a foundry, molten metal is poured into 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 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 risers from the casting. Runners, gates, and risers may be removed using cutting torches, band saws 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 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
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 weld multiple
castings or wrought metals together to form a finished
product.