Sand casting, also known as sand molding casting, is a time-tested casting method employing sand as the primary molding material.

The process involves pouring liquid metal into the sand mold to create the desired casting part.

It stands as one of the oldest known casting techniques and is renowned for its versatility in producing metal components, ranging from 1 kilogram to several tons.

In fact, over 61% of all metal castings are manufactured through sand casting.

Modern Advancements in Sand Casting

In contemporary industry, the sand casting process has undergone significant advancements in process control, material options, tolerance capabilities, and the ability to create intricate parts.

These advancements have bolstered its appeal, and it offers several unique advantages.

Advantages of Sand Casting

• Suitable for a wide range of metal types.
• Capable of producing large-sized and complex-shaped sand casting products.
• Comparatively lower tooling and equipment costs when compared to other metal forming processes.
• Scrap metal is recyclable.
• Offers short lead times.

Disadvantages of Sand Casting

• Porosity in sand casting can lead to reduced final part strength.
• Surface finish is often subpar, requiring additional cleaning.
• Cooled metal can exhibit shrinkage, resulting in poor dimensional accuracy.
• Low-tolerance products may necessitate secondary machining.

Applications of Sand Casting

The versatility of the sand casting process makes it ideal for producing a wide range of complex parts.

Its applications span various industries, showcasing its adaptability:

• Numerous pistons and valves.
• Blowers and impellers.
• Cams, bushings, and bearings.
• Electronic equipment components.
• Engine blocks.
• Bearings.
• Gears.
• Machine parts.
• Mining equipment components.
• Oil pans.
• Pump bodies and pistons.
• Screw nuts.
• Trailer components.
• Truck chassis parts.
• Valves.
• Water jackets and crankcases.
• Automobile parts.
• Screws, nuts, and gears.
• Agricultural machinery components.
• Medical equipment parts.

Despite being one of the oldest casting methods, the basic technique of sand casting remains unchanged.

It involves creating a cavity in the desired shape, and then pouring molten metal into it to produce finished products.

This simplicity, coupled with its adaptability, has made sand casting the most widely used metal casting method.

The Sand Casting Process: Step by Step

1. Sand Mixing: Preparation of molding sand and core sand by mixing old sand with an appropriate amount of clay.
2. Molding: Creating molds and core boxes based on part drawings, with wood, plastic, or metal molds depending on production needs.
3. Core-Making: Includes modeling (forming the casting cavity), core-making (forming the inner shape), and mold matching (placing the core and closing the molds).
4. Melting: Ensuring the correct chemical composition by melting alloy materials in a suitable furnace to obtain qualified liquid metal.
5. Pouring: Safely pouring molten iron from the furnace into the prepared mold to fill the entire cavity.
6. Clean-Up: After solidification, removing gates and shaking off excess sand before sandblasting to achieve a clean surface.
7. Casting Processing: Depending on requirements, processing and polishing may be performed using grinding wheels or grinders to remove burrs and enhance surface smoothness.
8. Casting Inspection: Generally performed during cleaning or processing to identify any defects. Some castings may require specific inspections.

In conclusion, the sand casting process remains a versatile and widely used method in casting production, especially for single-piece or small-batch castings.

While modern innovations have improved the process, the fundamental steps remain consistent.

Sand casting can accommodate a broad range of materials, including high-melting-temperature alloys, making it a valuable technique in various industries.

Materials for Sand Casting

Sand casting is versatile and can accommodate various alloys, including high-melting-temperature steel, nickel, and titanium.

However, the most common materials used in sand casting are:

• Aluminum alloys.
• Brass alloys.
• Cast iron.
• Cast steel.

Materials such as Aluminum 713 (Tenzaloy), Aluminum 535 (Almag 35), Brass C95400, Brass C95300, Brass C92600, Brass C93700, Brass C87500, Brass C83300, and others find applications in sand casting.

About Omicron Casting – Your Sand Casting Supplier

Omicron Casting is a reputable Sand Casting supplier based in China, known for providing high-quality castings for various industries.

They specialize in producing castings and offering machining services for a wide range of applications, including automotive, rail transit, food machinery, fluid chemical industry, engineering machinery, petroleum equipment, industrial locks, aerospace, and more.

Omicron Casting’s expertise encompasses materials such as low alloy steel, high manganese steel, wear-resistant cast iron, ductile iron, gray iron, stainless steel, carbon steel, and heat-resistant steel.

They employ various casting processes, including silica sol precision casting, water glass precision casting, resin sand casting, lost foam casting, and V method casting. Their production capabilities range from small single-piece castings to large-scale castings of up to 25 tons.

If you have inquiries about sand casting products or require casting services, consider contacting Omicron Casting for reliable solutions.