Melt

Badger Foundry maintains two primary melting sources (Cupola and Electric Furnace).   Extensive process control and chemistry analysis are performed by our in-house Metallurgical lab. Primary equipment is a spectrometer (17 elements) and a Leco for Carbon and Sulfur.  Each job is specifically identified on process cards as to chemistry, alloy requirements, pour temperature and hold times.  This detailed requirement allows each job to be specifically managed for metallurgical properties. We pride ourselves on the quality of our iron and maintain detailed records on each pour.

The Cupola utilizes metallurgical coke and blower to melt the metallics, this is our primary source for gray iron production.  The unit melts at a rate of 6.5 tons per an hour and channels into a 40 ton Ajax holding furnace.  Cupolas are well known for efficient melting and maintain a high level of nucleation of the iron.

The Electric Furnace is induction melt and is the primary source for our Ductile iron demands.  The furnace is capable of producing 2.5 tons an hour. Method of producing Ductile is a Tundish Ladle method.  Specifically prepared chemistry batches/heats for each casting,  in addition to chemistry analysis on spectrometer and Leco, nodularity rating is also reviewed and rated for each and every batch.