As explained in The Metal Casting’s article, “Foundry Processes,” foundries play a critical role in metal casting by transforming molten metal into finished products. The process involves creating molds and cores, melting the metal, pouring it into the mold, cooling, and finally removing and finishing the product. Foundries can be categorized into ferrous and non-ferrous facilities, depending on the type of metal they process.
The casting process begins with mold creation. Common materials include sand, metals, and investment materials. Sand molds, in particular, are widely used for their ability to withstand high temperatures, handle pressure, and allow gas escape during casting. The type of metal and the desired product shape determine the specific mold material.
Metal Melting and Casting:
Various furnaces, such as cupolas, electric arc, induction, hearth, or crucible furnaces, are used to melt metals. Once molten, the metal is poured into the pre-formed mold cavity, where it cools and solidifies before being separated from the mold. Each type of metal requires specific inputs, and the process generates varying byproducts.
Waste Management in Foundries:
Foundries produce three primary types of waste:
- Gaseous Wastes: Contain volatile and semi-volatile organic compounds, which can be captured using emission control systems.
- Liquid Wastes: Arise from water used for chilling metals or cleaning operations, which can be treated in water treatment plants.
- Solid Wastes: Include slag, spent sand, and refractories. Techniques like sand reclamation allow for recycling and reuse in other processes.
Additional foundry techniques include thermal galvanization and electroless nickel plating, used for specific applications to enhance metal durability.
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Article with all rights reserved, courtesy of themetalcasting.com.