Process

rigorous Process control

​Our Process

​​​​​​We work around the clock to keep our products up to the highest standard. Every employee at Waupaca Foundry is responsible for vigilantly watching over every step of our input and output processes. Cutting-edge technology and process control ensures your castings meet your specifications. We take quality seriously because you want the best, and we work to deliver it.

Raw Materials
 
With a tailored mix of recycled and virgin materials, we meet our customer’s specific requirements.  We use the best quality materials available, and ensure a continuous stock thanks to our production volume and trusted supplier relationships. Eight of our top ten supplier relationships go back 25 years or more, and we certify all suppliers through a defined, documented process.
 
 

Melting and Pouring Iron
 

We melt iron using large cupola and electric furnaces at temperatures ranging from 2,600 to 2,800 degrees Fahrenheit. Computerized systems monitor temperature constantly while the iron melts.

 
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Core Making
 

The core creates the interior surfaces of a casting. We design, build and maintain our own core box machines to provide a variety of core-making processes, each suited for the specific type of casting our customers require. ​

 
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Vertical Molding​​​​
 

A point of difference for Waupaca Foundry: 33 custom-built molding machines and time-tested process control. That’s how we’ve led the industry in delivering consistent high-quality castings. Designed, built and maintained by our engineering teams, these vertical molding machines produce more gray and ductile iron castings per hour than stock machines. We’re also more agile and flexible. 

 
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Shakeout
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As the iron travels down the molding line, the temperature gradually decreases from about 1,200 to 900 degrees Fahrenheit. Temperature at this stage varies based on the size of the casting as well as the molding rate. At the end of the mold line, castings enter a shakeout process where the molds are shaken off and the sand is recycled for reuse. The rapid cleaning of the mold sand allows for superior metallurgical results, and our multitude of shakeout options give our customers flexibility in sourcing decisions.

 

 

Cleaning and Finishing
 

When castings cool to below 140 degrees Fahrenheit, they are cleaned to remove residual sand and any other molding media from the casting surface. This ensures each finished casting meets your specifications.

 
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Inspection
 
Before castings are packaged and shipped, every one is visually inspected. Depending on the type of casting and customer requirements, we also employ vision inspection technology for defect identification. In addition, resonance frequency (RF) and ultrasonic tests assure conformance to specifications.
 
     

 

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