Raw material
We use a variety of iron blends to meet each customer’s unique requirements and all start with a customized mix of metals, recycled iron and scrap iron. We always source raw materials at the lowest possible price and are able to do so due to our production volume and long-term relationships with suppliers.
Melting iron
Iron is melted in large furnaces and stays at temperatures ranging 2,600 to 2,800 degrees Fahrenheit. Computerized systems monitor temperature constantly. >> Learn More
Core making
The core is used to create the interior surfaces of a casting. ThyssenKrupp Waupaca uses a variety of core making processes each suited for the specific type of casting our customers need. >> Learn More
Pouring iron and molding
Our difference: speed and customization. Our molding process is proprietary and customized giving customers a high volume, cost-effective process. We add speed by using an innovative double-pour process when pouring liquid iron.
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Shakeout
As the iron travels down the molding line, the temperature gradually decreases from about 1,200 to 900 degrees Fahrenheit. At the end of the mold line castings enter a shakeout process where the molds are shaken off the casting and the sand is recycled for reuse.
Cleaning
When castings get below about 140 degrees Fahrenheit, they are cleaned so residual sand and any other molding media is removed from the casting surface.
Finishing
The final step in our iron casting process involves grinding off any excess material left from the molding process and ensures the finished casting meets the customer’s specifications.