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Sand casting also called sand molded casting. It Is the process that utilizes non-reusable sand molds to form metal castings. Sand casting is used to produce a wide variety of cast iron
components with complex geometries.
In China, there are three types of sand casting techniques to make iron castings. They are precoated sand casting, resin sand casting and clay sand casting.
Among them, precoated sand casting is the most precision sand casting process with general casting tolerance CT8. It is able to produce iron castings less than 2kgs.
Clay sand casting is the second precision casting process with general casting tolerance CT9. Iron castings between 2kgs-60kgs are availble in this method.
And resin sand casting is mainly used for the production of large iron castings above 60kgs.
• Almost any ferrous and non-ferrous metals can be casted by sand casting
• Parts caan vary greatly in size, weight and shape. Weight can be from ounces to hundreds of tons
• Small quantity or large quantity
• Relative low cost for high volume parts
1. Mold-Making
Creating a mold is the first step in the sand casting process. Each casting needs a mold. A sand mold is formed by putting the sand into each half of the mold. The sand is stacked around the pattern,
which is a replica of the shape of the casting. When the pattern is removed, the cavity forming the casting remains. Any internal features of castings that cannot be formed by the pattern are formed
by separate cores made of sand before forming the mold. Mold making time includes positioning patterns, packaging sand and remove the pattern. Mold manufacturing time by the size of components,
the number of cores and the impact of sand. Lubricant is typically applied to the surface of the mold cavity to facilitate removal of the casting.
The use of lubricants also improves the flow of the metal and can improve the surface finish of the castings. The lubricant used is selected based on the temperature of the sand and the molten metal.
2. Pouring
After the mold is made, it must be prepared to pour the molten metal. First, the surface of the cavity is lubricated in order to remove the castings after casting.
Then, the core is positioned and the mold halves are closed and securely clamped together. It is necessary to keep the mold half sealed to prevent any loss of material.
The molten metal is kept at the set temperature in the furnace. After the mold is clamped, the molten metal can be cast from the holding vessel in the furnace and poured into the mold.
Pouring can be done manually or by automated machines. Sufficient molten metal must be poured to fill the entire cavity and all channels in the mold. Filling time is very short,
to prevent the early curing of any part of the metal.
3. Cooling
Once poured into the mold, molten metal begins to cool and solidify. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed. Until the end of cooling time, the mold can be opened. The cooling time required can be estimated from the wall thickness of the casting and the temperature of the metal.
Most of the possible defects are the result of the solidification process. If some molten metal cools too quickly, the part may shrink, crack or incompletely. Precautions can be taken when designing parts and molds..
4. Removal
After a predetermined set time, the sand mold can simply be broken and the castings removed. This step, sometimes referred to as getting rid of sand, is usually shaken by a vibrating machine and burned out of the bottle. Once removed,
the castings may have some sand and oxide adhering to the surface. Blasting is sometimes used to remove residual sand, especially from the inside surface, and to reduce the surface roughness.
5. Trimming
During cooling, the material from the mold channels solidifies on the part. These extra material must be manually trimmed by cutting or sawing or using a trimming machine. The time it takes to trim excess material can be estimated from the size of the casting. Larger castings require longer dressing times.
Waste from this trimming is discarded or reused during sand casting. However, it may be necessary to remediate appropriate chemicals for scrap before it is used in conjunction with non-recycled metals.
Investment casting is one option for creating intricate parts and components. There are several specific steps in the entire process to design and create the desired workpieces. It is named such because the workpieces are created around a shelled casting, which is later removed once the workpieces have been poured into the mold and are set.
Investment casting can produce a wide variety of products and prototypes, but it is important to choose the correct investment casting material for your application.
The right material helps you get the desired functionality, save on the cost of materials, eliminate unwanted casting defects, and limit the need for secondary processes after the casting is complete.
Investment Casting also known as precision casting or Lost wax casting, is a manufacturing process in which a wax pattern is used to shape a disposable ceramic mold. A wax pattern is made in the exact shape of the item to be cast. This pattern is coated with a refractory ceramic material. Once the ceramic material is hardened, it is turned upside-down and heated until the wax melts and drains out. The hardened ceramic shell becomes an expendable investment mold. Molten metal is poured into the mold and is left to cool. The metal casting is then broken from of the spent mold.
Final parts can display smooth surfaces and dimensional precision while allowing for lower weight, thin walls, or other beneficial properties.
Determining which properties can be successfully incorporated into your part largely depends on material choice.
Stainless Steel
Stainless steels feature superior durability in comparison with many other materials. The potential of the material has led to increased use in investment casting by designers and engineers.
Applications for stainless steel include gearbox parts in automotive applications, various gears, camp components, and golf club heads.
Low Alloy Steel
Low alloy steels are among the most frequently used steels in the mechanical world due to their affordability and beneficial mechanical properties.
Specialized heat-treating processes make it possible to engineer parts that have differing properties in different areas of the same workpiece.
For example, varying heat treatments can be used to make one surface tough and impact-resistant, while another surface becomes wear-resistant.
Aluminum Alloy
Aluminum alloy is the most used material in investment casting. Industries that use it most frequently include aerospace, avionics, electronics, and military.
Castings are now offered for demanding applications like airframe components thanks to the material’s improved strength and the availability of quality castings made from aluminum-silicon-magnesium alloy.
Carbon Steel
Carbon steel is a common low-cost material that comes in a variety of grades, with the classifications varying based on the amount of carbon content.
The strength, ductility, and performance of carbon steel can be improved in industrial applications through heat treatment.
Its ferromagnetic properties make carbon steel useful in motors and electrical appliances. It is safe, durable, and has a high structural integrity, making it one of world’s most frequently used alloys.
Super Alloy
Super alloys based in nickel and cobalt have common uses in the aerospace, energy, medical, chemical, and marine industries.
Nickel-based alloys are stronger at high temperatures and cobalt-based alloys have superior corrosion, oxidation, and wear resistance over their nickel-based counterparts.
Super alloys increasingly replace sheet metal because they provide high rigidity and superior service characteristics while remaining a cost-effective option.
Copper Alloy
Copper-based alloys are corrosion-resistant and feature low rates of wear. They are frequently used in applications such as ship or pump propellers, electrical components, and plumbing components.
A versatile material, there are more than 400 different alloys featuring a wide variety of properties.
Many part types can be investment cast from copper-based alloys. More common types of copper-based alloys include bronze and brass.
The strongest copper alloy is beryllium-copper, which has similar properties to high-strength alloy steels but with a higher corrosion resistance over longer periods.
Cast Iron
Iron castings, which often include gray iron and ductile iron, are known for their high accuracy and an affordable price tag.
Ductile iron has high strength, heat-resistance, and toughness, but it has a more complex production process than other steels. This leads to a higher production cost than cast steel.
Investment Casting Manufacturer
Looking for an innovative Investment Casting partner? One that provides outstanding service, exceptional quality, and low costs - all within short lead times? Look no further than Qianhao Casting, Inc. for your casting needs.
Different Investment Casting Products We have made for world Clients
Qianhao handles each job with an optimal process to achieve the lowest cost, best quality, and highest efficiency.
Investment Casting Foundry
Steadfast dedication to the field of precision casting and machining for 30 years, Qianhao is a globally recognized manufacturer of high-valued added and complex castings for global industry leaders.
Whether you require complex cast components weighing just a few grams or large components of up to 50 pounds, or your needs include high volume, rapid prototype, or short-run projects, you can count on the experience, innovation, and dedication of Qianhao Investment Casting to work for you.
Full-Service Casting Capabilities
Backed up by our modernized workshops, reliable equipment and advanced manufacturing technology, Qianhao is devoting to manufacturing high quality industrial products for our customers. .
We have abundance of experience in lost wax casting, lost form casting, shell molding, sanding casting, forging, precision machining, surface treatment, sheet metal, welding, and assembling which we would like to share with you and be of your service.
As for the custom finishing touches, Qianhao Precision Casting handles all plating and finishing. This includes phosphate coating, polishing, hand polishing, passivation, pickling and electropolishing.
Provide Our Customers with the Best Molding Solutions
We are Committed to Delivering the Highest Quality Investment Castings.
Rail parts Casting
Automotive Parts casting
Construction equipment casting
Forklif Equipment casting
Agricultural Machinery casting
We already have had cooperation with some the world's Top 500 companies as one of their major precision metal parts suppliers in China.
Sand Casting FAQ
Q1: What Is the Origin of Sand Casting?
A1:The origin of sand casting lies in pre-recorded history, dating back as far as the practice of metallurgy. It was the earliest and most universal technique for metal forming. Historical evidence confirms that sand casting was prevalent in Egypt (predating the first dynasty in 3,150 BC), Mesopotamia, and ancient China. The process clearly evolved independently in disparate and unconnected regions wherever metalworking and metal refining became established. .
Q2: Why Do We Use Sand Casting?
A2:The primary purpose of sand casting is to allow a low technology, low materials cost, and reliable method for forming high-quality metal components from a wide variety of pure metals and alloys. It is a versatile and cost-effective method for manufacturing complex or simple metal parts, and its primary beneficial purpose depends on the needs of the application. For example, sand casting can produce metal parts of a variety of complexities, from small and relatively intricate components to large, heavy castings, making it effective in a diverse range of applications..
Q3: How Does Sand Casting Work?
A3: Sand casting works by generating a mold by forming a packed sand body around a wooden or rapid prototype master/pattern (or a part to be copied/reproduced). This mold requires features related to gas venting, fill and thermal compensation volumes, and core support, and it can then be filled with molten metal, which cools in place to faithfully reproduce the sand cavity.
Q4: What Are the Types of Metals Used in Sand Casting?
A4: Sand casting is applicable to all metals other than exotics such as mercury and gallium. It is particularly well suited to high-cost/high-temperature materials such as titanium and nickel. It is most practical in the manufacture of relatively low cost and larger parts, often including some post machining to impose dimensional precision in the areas that require it. Metals commonly sand cast are: aluminum alloys, bronzes (gunmetal, nickel-aluminum bronze, etc.), steel, iron (nodular (gray), white, ductile, and malleable), brass, and stainless steels.