March 1, 2021 Sand Casting Advantages and Processes

This article looks at how sand casting works and its advantages.

Sand casting is a casting-based process that uses a sand mold. Because the cast is made for a specific item, sand casting has been used to cast metallic products of varying shapes, sizes, and weights. The process is so popular that it has been used in lots of different industries. In this article, we will look at how sand casting works and its advantages.

The Process

The process of sand casting starts with making the sand mold pattern. The pattern made on the sand will determine the size and shape of the product to be created. The second step is setting up the gating system. The gating system includes the pouring cup and gates that funnel the molten metal to different parts of the mold cavity.

Once the pattern and gating system is created, the mold pattern is removed. Because the sand has already taken the mold’s shape, it is no longer required. Once it is removed, molten metal can be poured into the mold cavity. Sand casting allows a manufacturer to use different types of metals including zinc, aluminum, tin, steel, iron, and bronze. The metal used depends on the product and may need to be heated to over 3000 degrees Fahrenheit to melt it and get it to flow easily.

The final step is removing the product for the mold. Once the metal is poured into the mold, the manufacturer has to wait for it to cool. Once it does, the mold is broken to remove the new metal casting. Although the mold pattern can be reused, the mold itself cannot and a manufacturer has to create a new mold for each product they create.

A Manufacturer Can Use Almost Any Alloy

One of the main advantages of sand casting is that it gives a manufacturer the freedom to use almost any ferrous or non-ferrous metal alloy. As long as the metal can be melted in a reasonable amount of time and without using too much power, it can be considered for use in sand casting.

Low Cost

Sand casting requires inexpensive tooling, and this is why it is a great process for smaller production runs. The patterns themselves can wear and the choice of material for the pattern will depend on its expected usage. Machined molds can be used for patterns that will be used for a long production run.

Time Savings

Sand casting is a quicker process than some of the other casting types. However, manufacturers have to think about the additional machining time because sand casting tends to produce rougher parts than other types of casting.

Versatility

Sand casting can produce products of different weights, sizes, and weights. The only limit to the type of product that can be produced is the size and shape of the mold pattern.

Compared to other types of casting, sand casting is a fast and inexpensive option. It can be used to quickly produce products and is a great option for limited runs. However, some machining may be required if there are some size and shape tolerances to be adhered to or to finish off the products.

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