Sand Casting
Sand mold casting is a widely used form of casting. As the name suggests, the mold is made of sand. Sand mold casting requires putting a finished part model or a wooden model (pattern) in the sand, and then filling the pattern with sand. After the pattern is taken out of the box, the sand forms a mold .
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 60% of all metal castings are produced via sand casting process.
Molds made of sand are relatively cheap, and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop the strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models called patterns, by carving directly into the sand, or by 3D printing.
Production Process
Molding and Core Making - Melting and Pouring - Knockout and Cleaning - gate cutting - Heat Treatment - Shot-blasting Treatment - Weld Repairing - Dimension and Appearance Inspection
Project Testing
Metallographic analysis - Impact testing - Tensile and bending testing - Spectrometric analysis - Brinell hardness testing - Magnetic testing(MT) - Leeb hardness testing - Uitrasonic testing(UT)
Our Sand Casting Capabilities
Typical | Feasible | |
Shapes: |
Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex |
Flat Thin-walled: Cylindrical Thin-walled: Cubic |
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Part size: | Weight: 1 oz - 450 ton | |
Materials: |
Metals Alloy Steel Carbon Steel Cast Iron Stainless Steel Aluminum Copper Magnesium Nickel |
Lead Tin Titanium Zinc |
Surface finish - Ra: | 300 - 600 μin | 125 - 2000 μin |
Tolerance: | ± 0.03 in. | ± 0.015 in. |
Max wall thickness: | 0.125 - 5 in. | 0.09 - 40 in. |
Quantity: | 1 - 1000 | 1 - 1000000 |
Lead time: | Days | Hours |
Advantages: |
Can produce very large parts Can form complex shapes Many material options Low tooling and equipment cost Scrap can be recycled Short lead time possible |
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Disadvantages: |
Poor material strength High porosity possible Poor surface finish and tolerance Seondary machining often required Low production rate High labor cost |
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Applications: | Engine blocks and manifolds, machine bases, gears, pulleys |