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Welcome to the Viking Pump foundry in Cedar Falls, Iowa, where we’ve been at the forefront of manufacturing gear pumps for decades. Our foundry is a cornerstone of our vertical integration capabilities, allowing us to produce castings and parts at speed.
Watch a video about our foundry here.
Location and Facility Overview
Located on Viking Road in the Cedar Falls Industrial Park, our foundry spans 78,000 square feet. Here, we utilize materials such as gray iron, carbon steel, 316 stainless steel, and 770 non-galling stainless steel.
The Casting Process
At the heart of any foundry is the casting process, where parts are created by pouring molten metal into a hollow mold. This process is not as simple as it sounds; it involves several key steps and skilled professionals to ensure quality and precision.
Creating the Mold
To create a mold, our core and mold technicians pull patterns for the various cast parts. Each pattern serves as a template for one side of one or more parts. The technique involves compressing sand against the plate, which captures the shape of the part, creating half of a mold.
Molten Metal Preparation
Experienced metallurgists test the molten metal to ensure the right temperature and chemistry are achieved. This is a critical step, as the quality of the metal will impact the final product.
When the metal is ready, our pouring team carefully pours it from the furnace into a waiting foundry ladle. Once poured, impurities are gathered at the top and removed from the crucible.
Timing and Precision
Timing is everything in this process. We must maintain the temperature of the metal high enough to pour the required number of parts.
Cleaning and Finishing the Castings
After cooling, the molds are broken open to reveal the rough castings. Each rough casting is cleaned, and any excess metal is cut away and recycled. Our chip and grind team then smooths out any rough edges.
Heat Treatment
Some materials, particularly stainless steel, require heat treatment. This process involves heating the parts in an oven and then cooling them in a water bath.
Transitioning to Machining
Once the castings are finished, they are moved to the casting shed, which serves as a bridge between the foundry and our machine shop. This transition point is where our pumps are machined and assembled, then shipped to distributors and customers around the globe.
Commitment to Quality and Innovation
At Viking Pump, we are committed to quality and innovation. By maintaining control over our manufacturing process through vertical integration, we ensure that each pump meets the highest standards.
In conclusion, Viking Pump’s foundry is a testament to our dedication to manufacturing excellence. From the initial mold creation to final castings, each step is important in ensuring a high quality product.