Grey Iron Castings/

Core Processes

Core processes involve the implementation of a block or barrier around which castings are made. The use of a core in this manner allows for the creation of internal cavities and re entrant angles in solid iron castings. A core may be used to create intricate gaps or hollows such as those found in gears and engine blocks, but are also common in the production of simple parts such as cast iron window frames which require the enclosure of large openings.

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Capital Pattern and Model, Inc.
Glendale Heights, IL
630-469-8200
Capital Pattern and Model is a leading provider of quality custom prototype castings and short-run castings in numerous alloys including grey iron, cast iron, zinc, and more. A state of the art in-house pattern and machine shop offers green sand casting, air set and plaster molding. This along with engineering assistance provides clients with cost effective quality castings and quick turnaround.
 
Bearon Corp.
Manheim, PA
717-898-2210
Since 1980, Bearon has been a top provider of grey iron castings and other components. Bearon components are crafted from aluminum, brass, bronze, cast iron, ductile iron and malleable iron to suit a range of industrial applications. With manufacturing capabilities including casting, machining, fabrication, finishing, molding and more, Bearon can take care of your projects from start to finish.
 
Bernier Cast Metals Inc.
Saginaw, MI
800-252-3657
Bernier Cast Metals manufactures quality sand castings in prototype, small and semi-production quantities. With green sand molding, air-set and lost foam casting, Bernier offers castings in all grey iron and ductile iron alloys with additional value added services. On-time delivery, competitive pricing, quality products and friendly service make Bernier the number one source for cast components.
 
Benton Foundry, Inc.
Benton, PA
570-925-6711
For nearly a century, Benton Foundry has been supplying iron castings to a variety of industries, building a reputation for consistent, high-quality castings delivered on time. Working with all types of gray iron and ductile iron, Benton provides quality components and extraordinary service at a low net cost. Put Benton's near 100 year history to work for your most challenging casting application.
 
Bremen Castings Inc.
Bremen, IN
800-837-2411
As a foundry & machine shop, Bremen Castings continues to grow & diversify. BCI keeps making its ISO 9001:2008 system better & better; customers receive world class green sand casting & precision CNC machining under one roof! Founded in 1939 with an emphasis on using recycled ferrous material, this 4th generation family business produces complete assembled, precision gray & ductile iron castings.
 
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Core Processes

Casting processes that employ cores are little if at all different from solid part manufacturing as core production is an operation performed separately. The pre-formed core is held in place with apparatus known as core prints or chaplets while molten metal is poured into the enclosed mold. Once the cavity has been filled, the material is cooled to promote solidification. The part is ejected from the mold and the core is in turn removed from the part. Shaking or breaking are commonly employed to remove the core and thus disposable or re-useable materials are popular in core processes as the item is used only once in many applications. While continuous use cores may be made of metals, ceramics or polymers; green or dry sand cores are popular in many applications as they are expendable and the materials are easily reclaimed for future use. Material considerations are important as each core must have adequate compression strength, permeability and refractoriness while maintaining a smooth surface that is easily broken down for removal or shakeout.

While the phrase core processes can be used to describe the casting methods of which they are an integral part, it may also apply to the manufacturing techniques used in the production of the core itself. While extrusion and injection molding may be used in some cases, casting is actually used to produce many of cores found in modern iron foundries. The first step is preparing the materials used to make the core. A continuous screw type mixer is used to combine sand and binders such as clay or pulverized coal to be used for the core. A special cast known as a core box is used to form the specific shape of core needed. The sandy slurry is either packed into and shaken out of a dump core box or injected into a split core box which opens for removal. The cores are then baked at variable temperatures which hardens them as needed for casting. If needed, multiple core segments can be joined with hot glue or other simple fasteners to create longer or larger cavities. As the use of sand may result in a rough surface, the core may be filed or grinded to smoother finish before use in grey iron casting. The method of core design and production varies based on the specific need and configuration of the part. Considerations for core processes and manufacturing include production rate and quantity, precision and surface finish.