Pattern Making:

The Pattern is a full size model of the part that makes an impression in the
sand mold, with dimensional allocation for shrinkage and finishing.
If the casting is hollow, additional patterns called cores are used to create
these cavities in the finished product.
Patterns are usually made of wood, plastic, metal, or plaster; however, other
materials or combinations of materials are used if there are additional
specific properties required of the pattern.
Every Pattern must have a draft angle of approximately 2° - 3° to all walls
parallel to the parting direction to facilitate removing the part from the mold.
Paint the surface of the Pattern with Varnish or Shellac to make it water tight
and to ensure that the sand does not stick.
For a Flat back pattern- put screw holes in the back to aid its removal from
the sand.

Molding:

Molding is the multi-step process in which molds are created.

In horizontal casting, the mold is contained in a two piece frame, called a
Flask. The upper portion of the flask is called a Cope and the lower portion is
a Drag.
First, molding sand is packed into a Flask around the pattern. After the
pattern is removed, Gating and Runner arrangements are positioned in the
drag half of the mold cavity and the Sprue is placed in the cope portion.
Gating systems are necessary for the molten metal to flow into the mold
cavity.
Cores are also placed in the drag portion of the mold if they are needed. To
finish the mold, the Cope (top) section is placed on the Drag (bottom)
section, and the mold is closed and clamped together.

Sand:
Two main routes are used for bonding the sand moulds:
The "green sand" consists of mixtures of sand, clay (Bentonite) and moisture.
If the sand can be squeezed together and hold its shape, it is suitable for
use.
The "dry sand" consists of sand and synthetic binders cured thermally or
chemically.
The sand cores used for forming the inside shape of hollow parts of the
casting are made using dry sand components.
Between uses, the sand is rejuvenated by adding water and mulling (mixing
and smashing). If you do not let the sand dry out all the way, you do not
have to mull, just add water. Sand grit is determined just like sandpaper. 150
is very fine and 50 grit is coarse. Fine sand will give good detail, coarse sand
will give a pebbly or rough texture.

MaterialsMelting temperature
Aluminum alloys1220 °F (660 °C)
Brass alloys1980 °F (1082 °C)
Cast iron1990-2300 °F (1088-1260 °C)
Cast steel2500 °F (1371 °C)
http://vimeo.com/3172887

http://www.scribd.com/doc/18543038/Sand-
Casting-Presentation
A Basic Overview
Metal casting is the process in which molten metal is poured into a mold and allowed to solidify into an
object. The object that results from this process is also called a casting. In sand casting, sand is used
to define the cavity inside a mold. In addition, sand is used to make any cores that are contained in
the mold. The molten metal solidifies in the cavity between the interior of the mold and the exterior of
the core. There are the five basic steps to creating a sand casting.

Patternmaking
The first step in sand casting is patternmaking. The pattern is a replica of the exterior of the casting
with dimensional allocation for shrinkage and finishing. If the casting is to be hollow, additional
patterns called cores are used to create these cavities in the finished product. Patterns are usually
made of wood, plastic, metal, or plaster; however, other materials or combinations of materials are
used if there are additional specific properties required of the pattern. The number of castings to be
made from the mold and the specifications required of the finished casting are two of the criteria that
determine which material is selected for the creation of the pattern.

Coremaking
The next step in the process is coremaking. Cores are forms which are placed into the mold to create
the interior contours of the casting. They are typically made of a sand mixture- sand combined with
water and organic adhesives called binders- which is baked to form the core. This allows the cores to
be strong yet collapsible, so they can be easily removed from the finished casting. Since cores are
made in molds, they require a pattern and mold, called a core box. The core pattern is made in the
same fashion as the casting pattern, but the core box is created from a durable material like metal or
wood. Since the cores are made of sand, the mold cannot also be made of sand.

Molding
Molding is the multi-step process in which molds are created. In horizontal casting, the mold is
contained in a two piece frame, called a flask. The upper portion of the flask is called a cope and the
lower portion is a drag. First, molding sand is packed into a flask around the pattern. After the pattern
is removed, gating and runner arrangements are positioned in the drag half of the mold cavity and the
sprue is placed the cope portion. Gating systems are necessary for the molten metal to flow into the
mold cavity. Cores are also placed in the drag portion of the mold if they are needed. To finish the
mold, the cope (top) section is placed on the drag (bottom) section, and the mold is closed and
clamped together.
In Metal Technologies' foundries, molds are created in large automated molding machines
(Disamatics), a process which warrants its own detailed explanation.

Melting & Pouring

Melting is the preparation of the metal for casting, and its conversion from a solid to a liquid state in a
furnace. It is then transferred in a ladle to the molding area of the foundry where it is poured into the
molds.After the metal has solidified, the molds are vibrated to remove the sand from the casting, a
process called shakeout.

Cleaning
Cleaning generally refers to the removal of all materials that are not part of the finished casting.
Rough cleaning is the removal of the gating systems from the casting. Initial finishing removes any
residual mold or core sand that remains on the piece after it is free of the mold. Trimming removes
any superfluous metal. In the last stages of finishing, the surface of the casting is cleaned for
improved appearance. In addition, at this point, the casting is inspected for defects and adherence to
quality standards. This inspection may include nondestructive testing to determine whether the part
will adequately perform for its intended use.

http://www.metal-technologies.com/SandCasting.aspx