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Sand casting remains one of the most cost-effective, widely used and efficient casting solutions, helping to reduce lead times and costs.
What is sand casting?
Sand casting is a metal casting manufacturing technique that involves using sand to create molds. This process is used to manufacture metal products of various shapes and sizes.
How does sand casting work?
The sand casting molding process consists of several steps. The sand casting process begins with the creation of a mold pattern and gating system. Each pattern requires a new mold designed to match the exact size and shape of the target part. The setup also requires a two-part casting flask called the cap and drag.
The mold model is placed in the sand and the gating system is provided with a series of tunnels and a pouring cup. After the sand is filled around the model, the model is removed, leaving the mold cavity.
The metal is then heated to high temperatures, turning the metal into a liquid state. The temperature required to melt the metal depends on the alloy. Some metals take longer to heat up.
The molten metal is poured into the mold cavity. After the metal is poured into the mold, the metal begins to cool and solidify. To remove the part, the sand mold is separated along the parting line. During this process, the mold cavity is destroyed. However, mold models are usually reusable.
History of Sand Casting
Casting metal from sand is the oldest method of metal casting and one of the most versatile. The earliest recorded use of sand casting is around 1540.
It wasn't until the high demand for cars and machines that the sand casting process became fully automated. Increased demand has also led to advancements in sand casting technology, including increased molding speeds and increased mold strength.
The following materials can be used in sand castings:
Stainless Steel/Duplex 2205, 2507 and Zeron
alloy steel
Gray Iron, Ductile Iron and White Iron
aluminum
Brass, Bronze and Copper
magnesium
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