Warsaw Foundry Company | Casting Excellence

Gray Iron Casting Services

Gray Iron Casting Services

Since 1923, the Warsaw Foundry Company has been providing quality castings from gray iron, ductile iron, and alloy gray iron, to customers in a wide range of industries. We specialize in green sand molding with wood, plastic, steel, and aluminum patterns, providing castings from 1 ounce to 150 lbs, in tensile strengths from 25,000 to 100,000 psi. We utilize various automatic and hydraulic equipment such as our Hunter molding machines that feature flask sizes of 14" x 19" and 20" x 24", and 14 shell core machines which gives us medium volume core making capabilities. We also offer squeezer match plates, which are handmade molds that can be used for item with flask sizes beyond equipment capacity, and utilize pneumatic and semi-manual processes. Squeezer and floor molding capabilities are available for short run and deep draw items. These capabilities which can achieve tolerances of ±.030", are supported by our Coreless induction furnace; this provides us with a melting capacity of 1.6 tons per hour.

Augmenting our comprehensive casting capabilities is our ability to assemble intricate cores, and provide pattern repair and set up in-house. Our operation is geared towards casting runs from a single piece to 20,000 pieces per month, depending on casting design and weight.

At Warsaw Foundry, we take quality seriously, our facility is ISO 9001:2008 certified and we can comply with various industry standards.

For more information on all of our gray iron casting capabilities, see the table below or contact us directly.

Warsaw Foundries Gray Iron Casting Capabilities

Molding Method
Green Sand
Pattern Types
Materials (Metals)
Gray Iron (Class 25, 30, 35, 40)
Ductile Iron (Grades 60-40-18, 65-45-12, 80-55-06, 100-70-03)
Alloy Gray Iron
Tensile Strength
25,000 to 100,000 psi
Casting Weight
1 ounce to 150 pounds
Tolerance (+/-)
+/- .030 typically
Corebox Capabilities
14 Shell Core machines: Dependendable-100, Dependable-200, Dependable-300, Redford HP-43, Shalco U-180 machines; oil sand bench and blow cores to 50# core weight.
Cold box cores and molds can be purchased from local vendors.
Molding Machines
1-Hunter 20 molding machine (flask size 20x24)
2- Hunter 10 molding machines (flask size 14x19)
Squeezer and floor molding capabilities for short run and deep draw type item.
Additional Services Provided
Core Assembly
Production Volume
Low to Medium volume (Short order/Job Shop)
Casting runs from 1 to 20,000 per month depending on casting design and weight.
Melting Capabilities
Coreless Electric Furnace - 5,000 pound capacity
Melting capacity 1.6 ton per hour

Additional Information

Industry Focus
Marine, Automotive, Municipal, Agricultural, Military, Motor and Pump Housings, Miscellaneous component parts.
Intended Applications
Water Jacketed Manifold
Water Pumps
Pump Bodies
Motor Housings
Generator Housings
End Castings
Air Compressor Housings
Miscellaneous component Parts for various industries.
Industry Standards
ISO 9001:2008
File Formats