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Sand Casting Service

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Sand Casting Service

Sand Casting is a traditional metal casting process that involves creating a mold from compacted sand, then pouring molten metal into the cavity to form a desired shape.

Once the metal solidifies, the sand mold is broken apart to remove the final casting.

DEZE Technology provides a variety of casting services, and users can choose the appropriate casting process according to their needs.

If you don’t know which casting method is more suitable for your product, please contact us and our professional engineers will help you.

What is Sand Casting

DEZE-Sand-Casting-Service

Detailed Steps of Sand Casting

Mustri tegemine

1. Mustri tegemine

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

It is usually made from wood, plastist, või metallist.

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

2. Hallituse valmistamine

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

The mold is made in two halves:

  • Cope (top half) ja 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.
Core-Making

3. Tuumade tegemine (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.
Metal Melting and Pouring

4. Metal Melting and Pouring

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

  • The system includes väravad (to direct flow), risers (to compensate for shrinkage), ja vents (to let gases escape).
  • Metals used: malm, alumiiniumist, terasest, pronks, jne.
  • Care is taken to avoid turbulence, gas entrapment, and inclusions during pouring.
Jahutamine ja tahkumine

5. Jahutamine ja tahkumine

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.
Shakeout and Mold Removal

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 raputus.
  • 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.
Puhastamine ja viimistlemine

7. Puhastamine ja viimistlemine

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

  • The surface may be puhastatud by shot blasting, tumbling, or pickling.
  • Mehaaniline töötlemine is performed as needed to achieve final tolerances.
  • Surface treatments or coatings (nt., maalimine, poleerimine) saab rakendada.

What materials are used in sand casting?

Sand casting supports a wide range of ferrous and non-ferrous metals. The choice depends on the desired mechanical properties, korrosioonikindlus, kaal, ja maksumus.

Ferrous Metals

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

Materjal Hinded Peamised omadused Tüüpilised rakendused
Hall malmist ASTM A48, EN-GJL-200/300 Suurepärane valatavus, vibratsiooni summutamine, survetugevus Mootori plokid, masinate alused, korpused
Kõrgtugev malm ASTM A536 (60-40-18), EN-GJS-400 Sitkus, plastilisus, väsimuskindlus Väntvõllid, hammasrattad, toruliitmikud, rasketehnika
Süsinikteras AISI 1020, AISI 1045, AISI 1060 Kõrge tugevus, tasuv, weldable Konstruktsiooniosad, võllid, industrial tools
Legeerteras AISI 4140, 4340, ASTM A387, EN 34CrNiMo6 Kuumakindlus, Karastus, improved wear resistance Käigud, sureb, pressure parts, kosmoselennundus
Roostevaba teras AISI 304, 316, 410, 420, CF8, CF8M Suurepärane korrosioonikindlus, hygienic, kõrge tugevus Food-grade equipment, ventiilid, pumbaosad, marine use

Non-Ferrous Metals

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

Materjal Hinded Peamised omadused Tüüpilised rakendused
Alumiiniumsulamid A356, A319, 6061, LM6 Kerge, korrosioonikindel, good conductivity, taaskasutatav Autotööstus, kosmosesõidukite osad, electrical enclosures
Pronks (Cu-Sn) C83600, C93200, Sae 660 Excellent wear/corrosion resistance Bushings, hammasrattad, merekomponendid
Messing (Cu-Zn) C36000, C37700, CW614N Hea töödeldavus, attractive finish, korrosioonikindel Plumbing fixtures, decorative hardware
Vask C11000, C12200 Outstanding electrical and thermal conductivity Electrical connectors, terminalid, bus bars
Zinc Alloys Zamak 3, Zamak 5, ZA-8 Madal sulamistemperatuur, excellent detail and surface finish Complex small parts, die-cast components
Magneesiumi sulamid AZ91D, AM60 Extremely lightweight, kõrge tugevuse ja kaalu suhe Lennundus, electronics housings, automotive panels

Advantages of DEZE Sand Casting

Advantages of DEZE Sand Casting
  • 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

Applications of Sand Casting

Sand casting’s versatility and low tooling cost make it ideal for a broad spectrum of applications—from heavy industrial components to artistic pieces:

Automotive & Transportation

Mootori plokid, silindripead, brake drums, jõuülekande korpused, suspension knuckles, and railway wheels.

Industrial Machinery & Equipment

Pumba korpused, klapi korpused, gearbox casings, compressor shells, and large machine bases.

Oil & Gas & Petrochemical

Pump and compressor internals, refinery equipment housings, piping tees, küünarnukid, ja äärikud.

Marine & Shipbuilding

Propeller hubs, rudder stocks, sea-water valve bodies, deck fittings (cleats, chocks), and anchor components.

Construction & Heavy Equipment

Excavator buckets, bulldozer blades, crane sheaves, and structural castings for mining gear.

Elektritootmine

Turbine casings, steam-generator housings, pump volutes, and hydropower turbine parts.

Põllumajandustehnika

Tractor housings, plowshares, combine-harvester components, and irrigation pump assemblies.

Art, Architecture & Decorative

Statues, relief panels, fountains, ornamental railings, and façade elements.

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Frequently Asked Questions about Sand Casting

TEENUS

1. What is sand casting?

Sand casting is a metal-forming process where a pattern creates a cavity in a sand-binder mixture, into which molten metal is poured.

Pärast tahkestamist, the sand mold is broken away to reveal the finished part.

2. Which metals can be used in sand casting?

Nearly any metal can be sand-cast, including ferrous alloys (gray and ductile iron, carbon and alloy steels) and non-ferrous alloys (alumiiniumist, pronks, messing, vask, tsink, ja magneesium).

3. How accurate is sand casting?

Typical dimensional tolerances are around ± 0.5 mm 100 mm of dimension, with surface finishes of Ra 6–12 µm.

4. What are the main advantages of sand casting?

  • Low tooling cost and rapid mold changes
  • Ability to produce very large or complex shapes
  • Broad material compatibility
  • Recyclable mold materials

5. What are the limitations of sand casting?

  • Relatively rough surface finish and looser tolerances
  • Higher scrap rate from gating and risers
  • Slower cycle times due to mold preparation and shakeout

6. How do I minimize casting defects in sand casting?

  • Design proper gating and risering for directional solidification
  • Use degassing and filtration to remove inclusions
  • Control mold compaction and venting to avoid gas porosity

7. When should I choose sand casting over other methods?

Select sand casting for low-to-medium volumes, large or complex parts, rapid prototyping, or when low tooling cost is a priority—even if final parts require some machining.

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