Sand Casting

Sand Casting is the most common metal casting process. In this process molds are made of sand and mixed with a bonding agent such as clay, then compacted around the three-dimensional pattern.

This approach is suited to all kinds of ferrous and nonferrous alloys, as light as 100 grams (0.2 lbs) with little or no weight limitations.

US Castings offers various sand casting processes:

Automatic vertical molding machine:

  • Suitable for gray & ductile iron parts
  • Optimal weight range of 0.1 kgs to 15 kgs
  • Large series runs
  • Tight and stable dimensional tolerances (see table below)
  • Good surface finish
  • High production efficiency (average of 300 units per hour)
  • Low tooling and unit costs for large series runs

Automatic vertical molding

Automatic horizontal molding machine:

  • Suitable for iron castings between 1 kg – 80 kgs
  • Minimum annual production runs of 20,000 units
  • Stable dimensions & mechanical properties
  • Good surface finish
  • Tight tolerances (see table below)

Semi-Automatic molding machines:

  • Suited for larger size castings ranging from 2 kgs to 150 kgs
  • Minimum of 1,000 units per annum
  • Stable dimensions
  • Low cost per kg most significantly in the 20 – 60 kgs item range.

Valve parts castings by semi-automatic and hand molding

Hand molding:

  • Ideal option for very large sized parts
  • Gray or ductile iron
  • Castings between 2 kg to 2 tons
  • Any annual quantity production runs

Resin sand mixer:

  • Suitable for large castings of greater than 100 kgs (220 lbs)
  • Can be adjusted to include most commercial alloys (based on sand binder selection)

Dimensional tolerance (based on international standard ISO 8062)

*Hand molding (CT9-CT12)Semi-Automatic molding (CT9)Horizontal molding machine (CT8)Vertical molding machine (CT7)BBasic dimension (mm)
1.5-4.21.510.71-10
1.6-4.41.61.10.7810-16
1.7-4.61.71.20.8216-25
1.8-51.81.30.925-40
2-5.621.4140-63
2.2-62.21.61.163-100
2.5-72.51.81.2100-160
2.8-82.821.4160-250
3.2-93.22.21.6250-400
3.6-103.62.61.8400-630
4-1142.8630-1000
4.6-134.63.21000-1600
5.4-155.41600-2500

* These tolerances also apply to steel castings

US Castings’ engineering department is available to consult on geometric complexity, surface finish, cost and other factors. US Castings’ expertise in Value-Engineering will help to achieve the desired result at the lowest possible unit or overall cost.

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