SAND CASTING

Grey (Ductile) Iron Castings, Steel Castings and Non-Ferrous Castings,C86500 Brass Castings

  

  

The sand casting process is used typically for larger parts and for small quantities of parts. Sand casting is capable of making fairly complex shapes using relatively inexpensive wood patterns.  Sand and containing a natural or synthetic binder, is packed around a wood pattern, the sand is then tamped down to provide the two-part mold with adequate strength. The pattern is then removed, leaving a negative form in the mold. Wooden models are used as material for the casting pattern at a relatively low cost. Due to relatively low tooling costs the casting method can be used for prototype manufacturing. The surface finish and casting tolerances are adequate for most purposes.

 

Casting products can vary greatly in size and weight, ranging from a couple ounces to several tons. Some smaller sand cast parts include components as gears, pulleys, crankshafts, connecting rods, and propellers. Larger applications include housings for large equipment and heavy machine bases. Sand casting is also common in producing automobile components, Marine products, Pump and Valve components, engine blocks, engine manifolds, Cylinder heads, and transmission parts.

Capabilities

  Typical Feasible
Shapes: Thin-walled: Complex
Solid: Cylindrical
Solid: Cubic
Solid: Complex
Flat
Thin-walled: Cylindrical
Thin-walled: Cubic
Part size: Weight: 1 lb - 10,000 lb
Materials:

Grey Iron, Ductile Iron

Carbon Steel, Alloy Steel
Stainless Steel
Aluminum
Copper

Titanium
Magnesium
Nickel

Required
Surface finish - Ra: 300 - 600 μin 125 - 2000 μin
Tolerance: ± 0.03 in. ± 0.015 in.
Max wall thickness: 0.125 - 5 in. 0.09 - 40 in.
Quantity: 1 - 1000 Pcs 1 - 1000000 Pcs
Lead time: Days Hours
Advantages: Can produce very large parts
Can form complex shapes
Many material options
Wooden and Low tooling and equipment cost
Scrap can be recycled
Short lead time possible
Disadvantages: Poor material strength
Porosity possible
Poor surface finish and tolerance
Seondary machining often required
Not higher production rate
High labor cost
Applications: Heavy Industry, Automotive components, Engine blocks and manifolds, machine bases, gears, pulleys and wind energy products.

Inspection: It is a very important testing of necessity for casting process!

Chemical Analysis

Every heat produced is analyzed for chemical composition by means of  X-ray fluorescence spectrometer. Our equipment is calibrated daily to national standards and custom made secondary standards. Dedicated instruments analyze for lighter elements carbon, sulphur, nitrogen and oxygen. Chemical analysis certificates are provided for every heat ordered.

 

Liquid Penetrant Inspection

Eddy Current

Radiography

Positive Material Identification

All incoming material is analyzed by a portable X-ray fluorescence spectrometer, This includes all lots of weld filler metal. Carbon levels are also checked in the chemical lab.

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