SAND CASTING

1
2
3
 Basic materials & equipment for sand-casting
Pattern
(a copy of the shape you want
to produce, made of wood,
plastic or metal)

Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish

Container of molten metal Top and bottom mold forms

(filled from furnace) (made of metal, open at top and bottom)

Rammer (tool to compact the sand; often a

pressing machine is used)

4
Basic summary of the sand casting process. . .

First of all,
mix the sand.

1
THEN MOLDING: 2 MOLDING:
Sand placed into Pattern placed into mold
bottom mold
form &
compacted

5
 3 MOLDING: Add A tube or pipe provides a
the top mold path to pour the metal in
form

Pattern is still inside!

4 MOLDING: Fill top form with

compacted sand.

6
 MOLDING:
5 Take the top mold off In the middle of the sand is
and remove pattern & a cavity shaped like the
pipe or post pattern!
Pouring
hole

6 MOLDING: Replace the top

mold and fasten securely!

7
 8 Wait for the metal to cool
(minutes to days, depending
7 CASTING: on the size of the casting)
Pour the metal (container is filled from
furnace immediately before you are
ready to pour)
8
 A copy of the pattern has
now been made in metal

9
CLEANING. Sand is cleaned
off the part, the “tab” where
metal flowed in must be
removed.

8 SHAKE OUT: Break apart the two halves of 10 Mold forms are reused
the mold & take out the part—usually
requires vibrating or striking the mold to Sand is broken up, screened
break apart the sand 11 to remove debris and
clumps, and sent for
remixing
9
 PATTERN
&
PATTERN MAKING

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
PATTERN MAKING
ALLOWANCES

34
35
36
37
38
39
40
MOLDING SAND

41
Molding Sand Constituents

42
43
44
Types of Molding Sand

45
46
47
48
49
50
51
52
CORE & CORE MAKING

53
54
55
56
57
58
59
60
61
62
63
64
65
SAND CONDITIONING

66
67
68
69
70
71
72
73
74
76
77
78
79
Melting Furnaces

80
81
Cupola

82
Construction of Cupola

83
84
Zones in Cupola

85
Working of Cupola

86
87
Electric Arc Furnace

88
89
Induction Furnace

90
91
92