Sand Casting
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Advantages of Sand Casting
Sand casting is often used because it produces castings with decent strength, structural density and pressure tightness at low cost. Equipment is cheap and easy to use, so skilled operators are not a requirement. Sand cores also allow for fairly complex shapes to be cast, as well as very large castings if needed. The molds are usually destroyed after each run, but the materials can be reused innumerable times. Other benefits include a wide alloy range, design flexibility, and tooling lead time with this process.
Sand Casting Materials
Sand Casting, or sand metal casting, is a process using sand as the molding material to produce metal castings. The term is also used to refer to the products produced by this process. Metals cast using the process include tin, cast iron, aluminum and steel, as well as copper and bronze. Sand casting is used to produce over seventy percent of all metal castings, some of these include metal tools, car parts and plumbing. These castings are produced in specialized foundries and factories, and the process is considered an economical option because it requires less technology and cost.
Process of Sand Casting
Sand is an ideal material for efficient metal casting because it is a refractory material and can withstand high temperatures. The sand is usually mixed with clay or other bonding agents and is moistened with water to establish the plasticity and strength of the mixture, which makes it suitable for molding. The mixture is held in a system of mold boxes or frames known as a flask. Compacting the sand around models or patterns, or carving directly into the sand creates the gate system and mold cavities. The basic process begins with placing a pattern in the sand to create the mold. Next, the pattern and sand are incorporated in a grating system. The pattern is then removed and the cavity filled with molten metal. Once the metal cools, the sand mold can be broken away and the newly produced casting removed.