Faircast, Inc. is rising to be the gray and ductile iron foundry powerhouse of the Midwest.  With multiple molding lines and a dedicated staff we can fit most of your casting needs.  We are prepared to help you from the quoting process all the way to shipping your product out the door.

WATERWALLED CUPOLA
Cupola is a continuous melting shaft furnace which has by its inherent design considerable advantages over batch type melters such as electric furnaces or rotary furnaces. A cupola can accept a wide range of raw materials including oily, wet and contaminated scrap. These materials are unsuitable for electric furnaces for safety reasons and because of the contamination their use is also often limited for metallurgical reasons. In cupola melting there is a degree of refining as the metal forms droplets during melting before collecting in the well. Many contaminants are lost or reduced in value in this process whereas when melting in electric furnaces or rotary furnaces whatever is in the charge material finishes up in the liquid.

INDUCTION MELTING
Induction furnaces are refractory lined crucibles with a water-cooled induction coil installed behind the refractory. The coil is powered by alternating current, which induces eddy currents in the metallic charge that generate heat. Induction furnaces allow for closer control of the metal analysis since the chemistry can be analyzed and adjusted if necessary before being tapped from the furnace.

SHELL CORE
Shell cores are made using resin coated silica sand that is invested (blown) into an iron core box. The core box is preheated to about 550 degrees Fahrenheit and the core(s) cure and become rigid due to the reaction between the resin and heat. The cores are yellow in color and are hollow, having a wall thickness of 1/8 to 3/4 inch depending on casting size and configuration. The hollow shell that forms the core gives it its name. Shell cores are made on vertically parted semi-automated machines yielding 20 to 60 cycles per hour. Shell cores provide the best cosmetics and dimensional tolerance of all the core processes.

ISOCURE
Isocure core process is a cold process where special binders are mixed with the sand immediately prior to being blown by compressed air into the core box. The binders are then set by a gas injected into the core box to make the core hard. Coldbox is the most popular core making process used to produce sand cores in today’s North American foundries.

DISA MOLDING
For your high volume applications, our 3 Disa vertical molding machines are available to produce parts in both ductile casting and gray iron casting.

(2) Disa Mark 5B 21″x26″
(1) Disa Mark 4A 20″x25″

AUTOMATIC MATCH-PLATE MOLDING
For your medium volume needs, we have three Beardsley and Piper match plate molding machines.

(1) B&P 16″x20″ Ductile and Gray Iron
(2) B&P 20″x26″ Ductile and Gray Iron

ROTOLIFT & SQUEEZER MANUAL MOLDING
Our Rotolift and Squeezer match-plate molding machines are designed for your low volume applications. Each machine is manually operated and we have varying flask sizes to produce a range of part sizes from 1-100 pounds. We pour gray and ductile iron on these molding centers.

(2) Rotolift 26″x36″ Largest Flask
(2) Squeezer 17″x17″ Largest Flask