Sand casting is a process that utilizes expendable sand molds to form near net shapes of metal components. It is a common production method for metal parts of all sizes, from a few ounces to several tons. Sand castings are not only versatile in the size of its products but they can also create exceptionally complex or detailed parts, and can be used to cast nearly any metal alloy.
The sand casting process involves the use of a furnace, molten metal, pattern, and sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand mold which is formed by the pattern. The sand mold separates along a parting line and the solidified casting can be removed.
Typical material used in sand castings
• Alloy steel
• Carbon steel
• High chrome steel
• Ductile iron
• Cast iron
Advantages of sand castings
• Inexpensive tooling
• Short lead time
• Alloy versitility
Process of metal sand casting
• 1. Place a pattern in sand to create a mold.
• 2. Incorporate the pattern and sand in a gating system.
• 3. Remove the pattern.
• 4. Fill the mold cavity with molten metal.
• 5. Allow the metal to cool.
• 6. Break away the sand mold and remove the casting.