A foundry produces castings by melting metal into a liquid, pouring it into a mold, and removing the mold material or casting after the metal has cooled and solidifies. Common metals processed are aluminum, cast iron, bronze, steel, and magnesium.
Manufacturing castings is one of the most common ways of producing a given part to an approximate size with minimal material waste. However, successfully processing molten metal to a quality casting can be challenging considering some of the variables with which foundries are faced. Some variables to consider are part size, geometry, and material cooling rates.
Due to the nature of this process, it’s common for castings to have defects above and/or below the cast surface. With this in mind, foundries usually have exact material quality specification requirements for castings to meet and use non-destructive testing (NDT) to confirm this. Radiography and ultrasonic inspections are typically used for locating subsurface defects. Magnetic particle and liquid penetrant are employed for the surface inspections.
Casting inspections are very common at American Testing Services. Our experience and knowledge cover a wide range cast parts used in the aerospace, wind, cryogenic, oil, and defense fields.