Since the dawn of time, mankind has been shaping things from metal. Earliest records speak of “stones from heaven”, referring to meteorites falling from the sky containing iron, the core ingredient of metal and metalworking.
Meteor falling from the sky
Around 9,000 BC, records acknowledge one of man’s first metal accomplishments, a bull-shaped gold ornament made from metalworking. From the Copper age, to the Bronze Age, and on into the Iron Age, man has been perfecting the craft of metalworking and metal casting. Over that time span, metal has been used to shape bowls, manhole covers, pipes, skillets, tools, and weapons.
During the Industrial Age, essentially 18th Century and onwards, 对机加工部件和复杂机械部件的需求使金属铸造达到了新的高度. Parts could no longer just be metal stamped or machined:
Metal casting was required!
Foundries are the very establishments that transform metal into metals castings. They engage in the pouring of metal into molds or dies, to form castings. Essentially, any hard metal that can be melted, can be cast.
There are various types of foundries involved in metal casting:
这些铸造厂之间的核心区别在于是否使用黑色金属或有色金属. Ferrous metals are those containing iron and non-ferrous metals do not contain iron. 这是一个重要的区别,因为危险和伤害的性质可能不同.
Iron, Grey Iron, and Steel. Ferrous Foundries are the most common casting foundry. Here are some products made from these metals:
Yep, a common engine block
10 points for whomever can identify the make
Engine blocks, machine tool frames, pipe-fittings, pumps, and valves
Guns, rifles, Aerospace, medical equipment, and high impact wear products.
Ferrous Foundries have a high number of recordable injury cases, with 6.1 for every 100 employees. Steel Foundries have the highest, with around 6.9 for every 100 employees.
A penny is made mostly of zinc
Silver, Platinum, Gold, Copper, Nickle Titanium, Aluminum, Tin, and Zinc
Nonferrous foundries have around 6.每100名员工中有3起可记录的案件,铝铸造厂大约有7起.8 recordable cases.
Depending on the complexity of the casting performed, foundries will follow a similar casting process.
Here is a look at the Casting Process:
该模式提供了所需部件或最终产品的精确复制品.
Example of a Gearbox pattern
准备模具,将液态金属倒入刚性框架中,形成铸件. 制芯功能包括将芯插入模具中,形成铸件的内部. Behind metalworking, this part of a foundry employs the most workers.
Core Making
Molten metal is poured into the mold.
Molten Metal being poured
Once the molten liquid has been poured, the mold cools rapidly.
During shakeout, the metal is removed from its mold. During Cleaning and Shot Blasting, focus is placed on the removal of sand.
Castings are heat treated, excess metal is trimmed and removed, castings are polished and the finished part is inspected.
There are roughly 115,000 workers employed in this industry. 以下是在工作时最需要个人防护装备的职业:
Click an occupation to expand and learn more.
Operate machines designed to cut, shape and form metal. There are roughly 56,020 of this ocupation found in Foundries. You will find these workers fabricating metal products, lifting heavy materials and working with their hands. Be sure to check out our Metal Fabrication industry educational page.
Operate casting or coremaking machines to mold or cast metal. Around 21,860 of this occupation works in foundries. You will find this worker operating casting, coremaking and metal forming equipment. Common Job titles for this position are Core Machine Operator, Mold Technician, and Die Cast Technician.
Operate cutting and forming machines. Roughly, 4.5% of the workforce falls into this occupation, roughly 9,850 workers. The majority of these workers are employed in Aluminum production. 你会发现这些工人更换切割工具,对准零件,检查金属工件. 这个职位常见的职位名称是数控机床设置,数控机械师和数控操作员. Exposure to hazardous equipment is always a concern.
Lubricates machines, changes parts, and performs machinery maintenance. There are a little over 3,980 of this occupation working in foundries. You will find these workers cleaning machine and machine parts. 清洁溶剂,油和金属加工液是这些工人明确关注的问题. Common Job titles for this position are Lubricator, Maintenance Man, and Oiler.
Operate grinding tools that remove excess metal material or burrs. There are around 7,410 of this occupation working in foundries. 你会发现这些工人在磨尖边缘和角落,同时抛光金属. 这个职位的常见职位是去毛刺,精加工,磨床和磨削操作员.
Inspectors, Testers, Sorters, Samplers, and Weighers - Inspect machined, fabricated or assembled parts. There are around 6,530 of this occupation working in foundries. Half of these workers are found in foundries. You will find these workers inspecting equipment and structures. 这个职位的常见职位是质量技术员、检验员和挑拣员.
操作计算机控制的机器或机器人对金属执行机器功能. There are around 3,730 of this occupation working in foundries. 你会发现这些工人正在拆卸和安装金属工件. Common job titles for this job occupation are Brake Press Operator, Machine Operator, and CNC Operator.
Pour and regulate the flow of molten metal into molds. There are around 4,060 of this occupation working in foundries. Are 56% of Pourers and Casters work in foundries. 你会发现这些工人把材料放在模具里,移动材料和操纵东西. 常见的职位头衔是普通铸造工、铸造工、熔炉操作员和炼铁工. Around 56% of this entire US occupation can be found in foundries.
Help move steel and other materials. Around 3,860 of this occupation works in foundries. That is a large number of hands needing protected. 你会发现这些工人操作传送带、运输材料和操作机器. Common job titles are Laborer and Operator.
职责包括提供或持有材料,以及清洁工作区域和设备. Around3,480 of this occupation working in foundries. 你会发现这些工人连接电缆,更换机器齿轮和处理大量的材料. All of these activities make gloves extremely important. 这个职位常见的职位名称是工人、新闻助理和物料处理员.
在铸造或建造各种类型的钢之前,操作熔化和精炼金属的熔炉. Furnace types include gas, oil, coal, electric arc or electric induction, open-hearth, or oxygen furnaces. There are roughly around 3,240 of this occupation working in Foundries. Around 24% of the entire US occupation works in Iron and Steel mills and 17.8% in Aluminum production. You will find these workers draining, transferring, and removing molten metal from furnaces and then placing into molds. Common Job titles for this position are Melt Room Operator, Vessel Operator and Central Melt Specialist.
Assemble finished products and parts. There are around 2,400 of this occupation working in foundries. You will find this worker assembling bolts, using many different types of tools, and moving heavy parts. They construct finished products and the parts that go into them. Assemblers and Fabricators use alot of tools, machines, and most importanly need their hands protected.
Use hand-welding, flame-cutting, hand soldering, and brazing equipment to weld/join metal components, fill holes, indentations, or seams of fabricated metal products. There are around 2,140 of this occupation working in foundries. 你会发现这些工人焊接组件在平,垂直或架空位置. 该职位常见的职位名称是维护焊工,Mig焊工和焊工/制造工
操作焊接,钎焊或钎焊机器,焊接,钎焊或热处理金属产品. There are around 2,270 of these workers found in Primary Metals. You will find these workers adding material to work pieces, joining metal components, and annealing finished work pieces. Common Job titles for this position are Fabricator, Mig Welder, Spot Welder, Fitter-Welder, and Braze Operators.
布置金属库存,操作机床,组装零件制造和维修模具. There are roughly 2,100 of these workers. 你会发现这些工人切割和塑造金属,以及组装机器夹具. 这个职位的常见职位是模具制造者,模具机械师和工具修理工.
操作锯、切、剪、开缝、打孔、卷曲、缺口、弯曲或拉直金属的机器. There are around 1,620 of this occupation working in foundries. 你会发现这些工人对准金属零件,磨掉毛刺或锋利的边缘. This makes cut resistant gloves a high priority for this worker. Common Job titles for this position are Die Setter, Press Operator, Machine Setter and Operator, Press Punch Operator.
Lay out, machine, fit, and assemble castings and parts to metal patterns, core boxes, or match plates. There are around 1,010 of this occupation working in foundries. 你会发现这个工人使用手工工具和操作研磨设备组装图案. 这个职业的常见职位是布局技术员,金属制模师和蜡模师.
All of these occupations have one thing in common; SAFETY is paramount while working in foundries.
For these workers, safety is not expensive, it is priceless.
From hot objects, to sharp metal, and flying particles, 工人需要他们可以信任和依赖的个人防护装备来完成工作并安全回家. We map out all the hazards below where newbb电子平台 Safety gloves, glasses and garments keep these workers protected and safe!
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Preparing casting molds is rough on a workers hands. With abrasive resistant gloves, your hands are protected.
Learn More About Abrasive Handling ProtectionHot-Casting work requires arms and hands covered with excellent protection. Good thing we manufacture an aluminized backed glove!
Metal casting involves liquids, moisture, and some hazardous chemicals like Benzene, Formaldehyde, and Sulfuric Acid, just to name a few. Check out the chemical protection offered.
Learn More About Chemicals and Liquids Protection
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Learn More About Hot Steam ProtectionEyewear hazards are everywhere in foundries, definitely when there is a lot of flying molten metal present. Do not worry; we have a wide variety of premier eyewear styles to choose from.
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Poor illumination throughout foundries requires workers needing visibility.
Learn More About Overall Visibility Protection
Handling mold plates can easily lacerate a worker's hands. Check out our cut resistant gloves.
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