Iron Castings | Metallurgy | Waupaca Foundry


Metallurgy at Waupaca Foundry

Each of our seven foundry operations has a fully functional metallurgical lab that performs chemical analysis, mechanical testing and microstructure analysis. Degreed metallurgical engineers support customer requirements and assist in quality control functions. Testing procedures are designed to eliminate trial and error and subjectivity of more traditional methods.


Resonant frequency tests the uniformity in a structure and the density of an iron casting to ensure the iron casting will not produce unwanted noise. In the case of a brake disc, this ensures rotors will operate without excessive vibration and/or noise.
Wedge penetration testing measures the tensile strength of an iron casting using a section of gray iron from an actual finished casting (not a cast bar).
Advanced thermal arrest system establishes the properties of the iron. By examining the solidification rate of the iron, metallurgists can determine the solidity of the iron casting. During the cooling process as iron goes from a liquid to a solid, it goes through phase transformations which release or absorb heat. By measuring these “events” we are able to predict if the iron casting will be solid and if the structure can be machined.
Tensile testing measures the tensile strength, yield strength and elongation for iron casting materials. Dimensions are very important for the accurate test result, so at Waupaca Foundry, we use a computer lathe, or CNC, to machine tensile bars to a high degree of accuracy so the sample is representative of how the iron casting will be machined. This ensures the castings meet required specifications.