Casting Services

Gray Iron

Gray Iron gets its name from its gray appearance caused by the presence of graphite flakes in its
microstructure. We pour Gray Iron with tensile strengths from 25,000 psi to greater than 40,000 psi.

Ductile Iron

Ductile Iron has higher overall strength and better wear than Gray Iron. Before failure it will exhibit
visible deformation unlike Gray Iron. We pour Ductile Iron with tensile strengths from 60,000 psi to 100,000 psi.

Warsaw Foundry Iron Casting Capabilities

Warsaw Foundry was founded in 1923 and later incorporated in 1949. For 100 years we have been providing quality iron castings to customers that serve multiple industries, including; automotive, agriculture, construction, energy, marine and municipal. Our molds are made from green sand and we
utilize wood, plastic, steel, and aluminum patterns that are provided by our customers to fit our automatic molding machines or conventional molding lines. Our automatic molding machines support flask sizes of 14″ x 19″ and 20″ x 24″. For flask sizes beyond the automatic equipment’s capabilities, we
utilize the conventional method of mold making for which pneumatic and semi-manual processes are needed. For jobs exceeding the conventional capabilities we will produce floor molds at a very low volume. The 5-ton induction furnace with a melting capacity of 1.6 tons per hour allows us to monitor pouring temperatures and forecast the grades of iron per by the part’s metallurgical requirements.

Supplementing our molding and melting capabilities is our shell core machines and our ability to assemble intricate cores for complicated castings. Additionally, we continue to produce cores the traditional way using oil sand and vertical stack baking oven. Warsaw Foundry is ISO 9001:2015 certified
and can comply with various industry quality standards.

Molding Method	Molding Method
Pattern Types	Wood Plastic Metal Aluminum
Materials (Metals)	Gray Iron (Class 25, 30, 35, 40) Ductile Iron (Grades 60-40-18, 65-45-12, 80-55-06, 100-70-03) Alloy Gray Iron
Tensile Strength	25,000 to 100,000 psi
Casting Weight	1 ounce to 150 pounds
Tolerance (+/-)	+/- .030 typically
Corebox Capabilities	14 Shell Core machines: Dependendable-100, Dependable-200, Dependable-300, Redford HP-43, Shalco U-180 machines; oil sand bench and blow cores to 50# core weight.Cold box cores and molds can be purchased from local vendors.
Molding Machines	1-Hunter 20 molding machine (flask size 20×24) 2- Hunter 10 molding machines (flask size 14×19) Squeezer and floor molding capabilities for short run and deep draw type item.
Additional Services Provided	Core Assembly
Production Volume	Low to Medium volume (Short order/Job Shop) Casting runs from 1 to 20,000 per month depending on casting design and weight.
Melting Capabilities	Coreless Electric Furnace – 5,000 pound capacity Melting capacity 1.6 ton per hour