Sand Casting Service

1. Creazione di mudelli

A pattern is a replica of the final part, slightly oversized to account for metal shrinkage during cooling.

It is usually made from wood, plastica, o metallu.

• Scopu: To create the mold cavity in the sand.
• Tipi: Split pattern (for complex parts), match-plate pattern, or cope-and-drag patterns.
• Shrinkage allowance: Typically 1–3% depending on the metal.

2. Moldu facendu

The pattern is placed inside a molding box (flask), è sand mixed with a binder (like clay or resin) is packed around it.

The mold is made in two halves:

• Cope (top half) è Drag (bottom half).
• The pattern is removed, leaving a cavity in the shape of the part.
• If required, cores are inserted into the mold to form internal features or hollow sections.

3. Creazione di core (If Applicable)

Cores are sand shapes inserted into the mold to form internal cavities in the casting.

• Made from core sand, which is more durable and heat-resistant.
• They must be accurately placed and often supported with chaplets (metal spacers).
• Cores are removed after casting, usually broken out and discarded.

4. Metal Melting and Pouring

Molten metal is prepared in a furnace and poured into the mold through a sprue è runner system.

• The system includes Porta (to direct flow), risers (to compensate for shrinkage), è vents (to let gases escape).
• Metals used: ghisa, aluminiu, azzaru, bronzu, ecc.
• Care is taken to avoid turbulence, gas entrapment, and inclusions during pouring.

5. Raffreddamentu è solidificazione

After pouring, the metal is allowed to cool and solidify inside the mold.

• Cooling rates affect grain structure and mechanical properties.
• Proper riser design ensures that metal shrinkage is compensated to avoid internal voids.
• The solidification time depends on part thickness and metal type.

6. Shakeout and Mold Removal

Once the metal has cooled, the sand mold is broken apart to retrieve the solid casting.

• This step is called Shakeout.
• The sand can often be recycled after cooling and screening.
• The casting is rough at this point and may have residual sand or oxide layers.

7. Pulizia è Finitura

Excess material such as sprues, risers, and flash are removed by cutting or grinding.

• The surface may be puliti by shot blasting, tumbling, or pickling.
• Machining is performed as needed to achieve final tolerances.
• Surface treatments or coatings (p.e., pittura, lucidatura) pò esse applicatu.

Sand casting supports a wide range of ferrous and non-ferrous metals. The choice depends on the desired mechanical properties, resistenza à a corrosione, pesu, è costu.

Ferrous Metals

These metals contain iron and are commonly used for high-strength and structural applications.

Non-Ferrous Metals

These are metals without significant iron content, typically used for corrosion resistance and weight savings.

• 1. Cost-Effective for Low to Medium Production
• 2. Wide Range of Material Compatibility
• 3. No Size Limitations
• 4. Complex Geometries Possible
• 5. Short Lead Time
• 6. Recyclable Materials
• 7. Suitable for a Variety of Surface Finishes