Foundry Shop

Overview

The Foundry Shop teaches the casting process from sand to solid part. Learners test moulding sand, prepare moulds in moulding boxes, melt and pour metal and clean the finished castings, with an introduction to powder metallurgy.

Because casting quality depends on many variables – sand properties, gating, temperature and cooling – the shop is also where students learn to recognise casting defects and their causes. ASFAN designs, supplies, installs and commissions the complete Foundry Shop, with operating manuals, experiment sheets and instructor training.

Key Equipment

Sand testing

• Grain fineness number (GFN) apparatus – fineness and distribution of sand grains
• Moisture content tester – moisture level of moulding sand
• Sand compression strength tester – strength of rammed sand
• Permeability meter – how easily gases escape through the mould
• Clay content apparatus – clay percentage in moulding sand
• Universal sand strength testing machine – green and dry sand strength

Melting, cutting and moulding

• Muffle furnace – heat treatment and high-temperature tests
• Plasma arc cutting machine with compressor – cutting gates, risers and plates
• Copes, drags and moulding boxes – two-part sand moulds
• Hand tools: shovel, trowel, rammer, riddle, lifter, water can – mould preparation and finishing
• Runner and riser patterns and pipes – gating-system practice

Learning Objectives

By the end of the training, learners will be able to:

• Explain casting principles and the process variables that affect casting quality.
• Select suitable materials, tools and equipment for different casting jobs.
• Carry out mould preparation, melting, pouring and fettling safely.
• Identify common casting defects and recommend remedies.

Career Relevance

Foundry skills lead to roles in production, quality control and industrial research.