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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

Nggawe Pola

1. Nggawe Pola

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

It is usually made from wood, plastik, utawa logam.

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

2. Medahan nggawe

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

The mold is made in two halves:

  • Cope (top half) lan 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. Inti Making (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 lan runner system.

  • The system includes gapura (to direct flow), risers (to compensate for shrinkage), lan vents (to let gases escape).
  • Metals used: wesi tuang, alumunium, waja, gangsa, lsp.
  • Care is taken to avoid turbulence, gas entrapment, and inclusions during pouring.
Cooling lan Solidification

5. Cooling lan Solidification

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 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.
Reresik lan Rampung

7. Reresik lan Rampung

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

  • The surface may be di resiki by shot blasting, tumbling, or pickling.
  • Mesin is performed as needed to achieve final tolerances.
  • Surface treatments or coatings (contone., Lukisan, polishing) bisa ditrapake.

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, resistance karat, bobot, lan biaya.

Ferrous Metals

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

Bahan Gelar Properties Key Aplikasi Khas
Wesi cast abu-abu Astm A48, EN-GJL-200/300 Castability banget, Gelak Damping, kekuwatan kompresif Blok mesin, dhasar mesin, Housings
Besi ulet ASTM A536 (60-40-18), EN-GJS-400 Tangguh, daktilitas, Resistensi Lemu Crankshafts, gir, fitting pipa, mesin abot
Baja Karbon AISI 1020, AISI 1045, AISI 1060 Kekuwatan dhuwur, larang regane, weldable Bagian struktural, shafts, industrial tools
Baja Paduan AISI 4140, 4340, ASTM A387, EN 34CrNiMo6 tahan panas, Hardenity, improved wear resistance Gaman, mati, pressure parts, aerospace
Baja tahan karat AISI 304, 316, 410, 420, CF8, Cf8m resistance karat banget, hygienic, kekuatan dhuwur Food-grade equipment, klep, Pompa Pag, marine use

Non-Ferrous Metals

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

Bahan Gelar Properties Key Aplikasi Khas
Aluminium Alloys A356, A319, 6061, LM6 entheng, tahan karat, good conductivity, daur ulang Otomotif, bagean aerospace, electrical enclosures
gangsa (Cu-Sn) C83600, C93200, Sae 660 Excellent wear/corrosion resistance Bushings, gir, komponen segara
Kuningan (Cu-Zn) C36000, C37700, CW614N Good machinability, attractive finish, tahan karat Plumbing fixtures, decorative hardware
Tembaga C11000, C12200 Outstanding electrical and thermal conductivity Electrical connectors, terminals, bus bars
Zinc Alloys Zamak 3, Zamak 5, ZA-8 Titik lebur rendah, excellent detail and surface finish Complex small parts, die-cast components
Magnesium Alloys AZ91D, AM60 Extremely lightweight, rasio kekuatan-kanggo-bobot dhuwur Aerospace, 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

Blok mesin, sirah silinder, brake drums, omah transmisi, suspension knuckles, and railway wheels.

Industrial Machinery & Equipment

omah pompa, awak katup, gearbox casings, compressor shells, and large machine bases.

Oil & Gas & Petrochemical

Pump and compressor internals, refinery equipment housings, piping tees, Elbows, lan flange.

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.

Generasi Daya

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

Mesin Pertanian

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

Art, Architecture & Decorative

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

Lapangan mobil

Lapangan mobil

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Lapangan militèr

bagean casting peralatan militer

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Frequently Asked Questions about Sand Casting

LAYANAN

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.

Sawise solidifikasi, 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 (alumunium, gangsa, kuningan, tembaga, seng, lan magnesium).

3. How accurate is sand casting?

Typical dimensional tolerances are around ± 0.5 mm saben 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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