Foundry

Fra Burmeister og Wains jernstøberi

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A Foundryman, Daniel Albert Wehrschmidt, 1899

Gussmetallschmelze

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Automation of foundry with robot

Born bronze - Bronze casts

Foundry is a specialized facility used for metallurgical processes, where metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries.

History

The history of foundries is intertwined with the history of metallurgy and the advancement of human civilization. Early foundries date back to around 3200 BCE in the Middle East, where the first known castings—copper frog statues—were produced. The process and complexity of foundry work have evolved significantly over millennia, from the basic pit furnaces and simple molds of ancient times to the highly sophisticated processes and equipment used in modern foundries.

Types of Foundries

Foundries are categorized based on the type of metal cast, the casting process used, and the kind of product produced. Major types include:

• Iron foundries, focusing on cast iron and ductile iron castings.
• Steel foundries, specializing in carbon, alloy, and stainless steel castings.
• Non-ferrous foundries, dealing with metals like aluminum, bronze, brass, and magnesium.

Each type of foundry uses specific processes suited to the properties of the metals they work with and the requirements of the final cast products.

Foundry Processes

The main steps in the foundry process include patternmaking, molding, melting and pouring, cooling, and finishing.

• Patternmaking: Creating a physical model of the casting, usually made from wood, metal, or plastic, which is used to form the mold cavity.
• Molding: Preparing the mold into which the molten metal will be poured. Molds can be made from materials such as sand, metal, or ceramic.
• Melting and Pouring: Melting the metal in a furnace and pouring it into the mold.
• Cooling: Allowing the cast metal to solidify within the mold.
• Finishing: Removing the casting from the mold and completing any necessary finishing touches, such as grinding or machining.

Equipment

Foundry equipment includes furnaces for melting metal, ladles for transporting and pouring molten metal, molds and cores for shaping the castings, and various machines for finishing and testing the final products.

Safety and Environmental Considerations

Foundries are hazardous environments, with risks including exposure to high temperatures, molten metal, and harmful gases. Safety measures are critical and include protective clothing, training, and ventilation systems. Environmental concerns in foundries involve managing emissions, waste materials, and energy consumption, with ongoing efforts to develop more sustainable practices.

Future of Foundries

The future of foundries lies in technological advancements, including automation, digitalization, and the use of advanced materials. These innovations aim to improve efficiency, reduce environmental impact, and meet the increasingly complex demands of industries such as aerospace, automotive, and construction.

Foundry Resources
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