Foundry technician's daily routine and methods
From form to finished workpiece
As a foundry technician you have your daily routine at a foundry where metal is melted and cast. The work ranges from planning and mould making to the casting itself and finishing the final product.
§The form is the starting point
It all starts with the mould. It is the mould that gives the workpiece its shape. A typical task is to make calculations and drawings for a casting mould or a model, and then produce the mould into which the molten metal is poured.
Sand moulds
Sand moulds are made by pressing a mould in sand around a model. They are flexible and well suited to complex pieces. When the metal has solidified the sand mould is broken and the piece is removed.
Fixed shapes.
Fixed molds can be used again and again and are suitable when you need to make many identical items. They last longer than sand molds and give consistent results in series production.
§Melting and casting
When the mold is ready, the metal is melted. It's about heating iron, steel, or other metal until it's liquid, then pouring it into the mold. Getting the temperature and pace right is critical for a good result.
Pressure casting
With pressure casting the molding material is pressed into the mold under high pressure. This gives good mold filling and is used among other things when the workpieces should be precise and uniform.
§Post-treatment and testing
When the piece is solidified and removed it's rarely completely finished. It often needs cleaning sanding or machining and is tested to ensure it meets requirements. Post-processing and quality assurance are important parts of the process.
“A good cast item starts long before the metal is melted. It starts with a well-thought-out mould.”