Sand casting is an efficient and economical process that uses sand to shape metal products. The mold container is prepared with a relief pattern, and sand, water, and clay are added. Two methods of solidifying sand are green sand and air-set casting. Two-part casting molds are used for irregular figures, and the sand can be recycled. Sand casting is used to create many metal products, with over 70% of metal castings made this way.
Sand casting is a process that uses sand as the primary material to shape various metal products. This molding method is very efficient because sand is a refractory material, which means it can withstand very high temperatures. It is also a very economical process, as it requires less cost and technology.
The first step in the sand casting process is to prepare the mold container. The container can be made of wood or metal, into which a relief pattern is inserted. Sand is then poured onto the model. Other elements such as water and clay are usually added to make the sand more compact and solid.
There are two common methods of solidifying sand. The first approach is using green sand. The word “green” does not refer to its color, but is used as an indication of its humidity. To prevent the sand from being too liquid, only 2 to 4% water is used. A green sand casting generally produces a rough surface on the finished metal product.
The air-set approach of sand casting is more commonly used, especially in factories and foundries. This method uses dry sand, along with other ingredients like clay and adhesive, to produce a cast. As the mixture is poured into the container, it is often tamped to avoid pinholes. Sometimes, the container is even vibrated to achieve a smooth and uniform pour. Many manufacturers prefer air casting because it creates a smoother texture on the finished product.
For three-dimensional or irregular figures such as a metal cube or hammer, a two-part casting mold is used. Both the top and bottom of the mold contain halves of the pattern. When the parts are sealed together, hot metal is poured through a hole called a “port” and the metal is contained in the compartment until it cools and solidifies.
Sand casting is usually destroyed after each use, but the sand itself can be recycled to make another casting. This lengthy process becomes a disadvantage if a product has to be produced in large quantities in a short period. The common metals that are smelted are aluminum, cast iron, tin, and steel. Bronze and copper can also be smelted in sand. Many metal tools, plumbing fixtures, and even car parts are made by sand casting. Reports in 2003 show that over 70 percent of metal castings are created by sand casting.
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