Casting Sand For Industrial Use

Posted on Oct 26, 2020

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Casting sand for industrial use

There are many people who use the names of foundry sand interchangeably with quite different foundry processes. There are several types of castings in the world of metal casting, but each of them is universally applicable. This is the only way and reason why we like to cooperate with our clients, so the right casting is implemented for their specific project.

The casting processes in comparison are not similar to the names of the processes. This means that die casting is a completely different procedure to sand casting, and we can help you determine which type of casting is best for your project.

 

What is a Die Casting?

Die casting is a process by which liquid or molten metal is forced into a die under high pressure. The die refers to a steel mold formed in the shape in which the product will be made. When the metal cools down and solidifies, you get the product that has just been manufactured. The mold is then closed and prepared for the next flooding.

 

The Sand Casting Differences

In sand casting, the liquid metal is poured directly into the mold in the sand and there is no high pressure. As the metal cools, the mold opens and removes sand from the product. However, this procedure requires longer downtimes as the sand around the pattern plate must be replaced after each casting. For this reason, it is best to use sand casting when fewer parts are needed.

Sand casting is characterized by the use of sand as the mold material. A pattern is applied around which the sand compacts. This creates a recess in the form of a cast piece. The sand used is a mixture of silica grains with 5–20% clay or bentonite and 2–8% water. Sand can be formed by hand or machine.

Sand casting can be used for cast iron, copper, and aluminum alloys and steel. It is commonly used for some auto parts.

:: Read more : Introduction to Cast Iron Castings

 

What Are Some Advantages Of Sand Casting?

The main advantage of sand casting is lower production costs. Other advantages include:

  • The possibility of making very large elements.
  • Exact for the ferrous and non-ferrous ingredients.
  • Low tooling cost after casting.
  • The disadvantages of sandblasting

However, sand casting also has some disadvantages:

  • It provides a lower degree of accuracy and is therefore not suitable for precision parts of a fixed size and weight.
  • It carries additional material to be processed, as a result of which it weighs more. This increases the cost of the parts.
  • Products usually have a rough surface.
  • The cooling rate is slow, resulting in a looser grain boundary as the sand mass needs to cool down.
  • The sand mold is opened after casting, which means you need to make a new mold for each object casting.

 

How Can A Permanent Mold Casting Help Me?

Permanent mold casting, on the other hand, uses a reusable mold made of steel or copper alloy. The mold is then coated with a graphite compound to keep the cast metal from sticking to the mold.

Advantages of permanent mold casting

The main advantage of die casting is the much greater accuracy of the casting. Some more benefits include:

  • Safer for the environment. The mold itself produces no waste and can be reused or recycled at the end of the cycle.
  • The casting cools down very quickly and the part is often ready in seconds. Which makes the grain edges much accurate. In fact, we can guarantee a minimum conductivity of 98% IACS, and castings routinely exceed it.
  • The part is more homogeneous, eliminating hot spots or weak connections.
  • The part usually has greater strength.
 

Some Disadvantages of permanent mold casting

Permanent mold casting has one particular disadvantage, namely the high cost of the mold. This makes it ineffective for small production runs and is often only used when accuracy is critical.

Permanent mold is better

If you manufacture parts that need to be manufactured with high accuracy and to tight tolerances, cold mold casting is your friend. Despite its initial cost, permanent in-mold casting can provide parts with high strength, excellent surface finish, and better dimensional tolerances.

Although permanent mold casting is not suitable for prototypes or small quantities due to the cost of the molds, the cost is worth it when looking at a larger series. Due to the high level of conductivity and the absence of weak joints, permanent cast parts can handle anything you want to throw at them.

Sand casting is a process where molten metal is cast into a mold made of a sand mixture. In the past, the process was only cost-effective for small series production. But now it is also suitable for high volume production thanks to the automated sand mold equipment.

Sand castings sometimes have a rough surface with surface contamination and surface changes. This process typically produces medium to large parts such as valve bodies, crankshafts, and engine blocks. The dimensional accuracy and surface finish of the casting depend on the type of sand and the forming process.

Two main types of sand are used for molding: green sand and dry sand. Green sand consists of quartz sand, clay, moisture and other additives. Dry sand is a mixture of sand and a quick-curing glue. When dry sand is used, it is often referred to as baking moldless casting or air-bonded sand casting. Castings made of coarse green sand tend to have a rough surface, while air-dried molds can produce castings with much smoother surfaces.

 

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