Sand Casting

Sand casting is a traditional and widely used metal casting technique.

In this process, molten metal is poured into a sand mold and allowed to cool and solidify. The sand mold is then broken apart to retrieve the casting. Sand casting is known for its low production cost and broad applicability, making it particularly suitable for large and complex parts.

Materials include

Cast Iron: The most common sand casting material, suitable for producing various structural components such as machinery bases, pipes, and valves.
Steel: Ideal for high-strength, wear-resistant parts like gears and bearing housings.
Aluminum Alloys: Lightweight and corrosion-resistant, suitable for automotive parts and appliance housings.
Copper Alloys: Such as bronze and brass, which are ideal for wear-resistant and corrosion-resistant components.

Advantages:

Low Cost: Sand molds are inexpensive, and the mold-making process is simple, making it suitable for large parts or low-volume production.
Wide Applicability: Can be used to cast various metals, including high-melting-point metals.
Large Part Production: Capable of producing very large parts with virtually no size limitations.
High Flexibility: Can create complex shapes, including hollow and porous structures.

Disadvantages

Rough Surface Finish: The surface of sand molds is relatively rough, so sand-cast products usually require post-processing for a smoother surface.
Lower Precision: Sand castings have lower dimensional accuracy compared to other casting methods.
Slow Production Speed: The sand casting process requires time for mold-making and cooling.
Lower Mechanical Properties: Sand castings may contain pores or other defects, which could affect mechanical performance.

Applications

Machinery Industry: Used to manufacture large machine bases, gears, pulleys, and other machine components.
Automotive Industry: Used to produce engine blocks, exhaust manifolds, brake drums, and more.
Construction and Infrastructure: For making cast iron parts like valves, manhole covers, and railings.
Energy Industry: Used in large equipment such as wind turbine components and turbine housings for hydropower plants.
Shipping and Marine Engineering: For producing ship propellers, ballast, and other large marine equipment.