Sand Casting

Advantages Disadvantages Recommended Application

Least Expensive in small quantities (less Dimensional accuracy inferior to other Use when strength/weight ratio permits
than 100) processes, requires larger tolerances
Tolerances, surface finish and low
Ferrous and non - ferrous metals may be Castings usually exceed calculated weight machining cost does not warrant a more
cast expensive process
Surface finish of ferrous castings usually
Possible to cast very large parts. exceeds 125 RMS

• Least expensive tooling

Permanent and Semi-permanent Mold Casting

Less expensive than Investment or Die Only non-ferrous metals may be cast by Use when process recommended for parts
Castings this process subjected to hydrostatic pressure

Dimensional Tolerances closer than Sand Less competitive with Sand Cast process Ideal for parts having low profile, no cores
Castings when three or more sand cores are and quantities in excess of 300
required
Castings are dense and pressure tight
Higher tooling cost than Sand Cast

Plaster Cast

Smooth "As Cast" finish (25 RMS) More costly than Sand or Permanent Use when parts require smooth "As Cast"
Mold-Casting surface finish and closer tolerances than
Closer dimensional tolerance than Sand possible with Sand or Permanent Mold
Cast Limited number of sources Processes

• Intricate shapes and fine details Requires minimum of 1 deg. draft
including thinner "As Cast" walls are
possible

• Large parts cost less to cast than by

Investment process

Investment Cast

Close dimensional tolerance Costs are higher than Sand, Permanent Use when Complexity precludes use of
Mold or Plaster process Castings Sand or Permanent Mold Castings
Complex shape, fine detail, intricate core
sections and thin walls are possible The process cost is justified through
 savings in machining or brazing
Ferrous and non-ferrous metals may be
cast Weight savings justifies increased cost

As-Cast" finish (64 - 125 RMS)

Die Casting

Good dimensional tolerances are possible Economical only in very large quantities Use when quantity of parts justifies the high
due to high tool cost tooling cost
Excellent part-part dimensional
consistency Not recommended for hydrostatic Parts are not structural and are subjected
pressure applications to hydrostatic pressure
Parts require a minimal post machining
For Castings where penetrant (die) or
radiographic inspection are not required.

Difficult to guarantee minimum mechanical

properties

Casting enables pieces to be combined into a single part, eliminating,assembly and inventory. Compared to machined parts, costs
are much less. Virtually any metal that can be melted is cast.

The size can be from a few grams (for example a watch case) to several tones (marine diesel engine) the shape from simple
(manhole cover) to complex (6-cylinder engine block). Order size from one-off (paper mill crusher) to massive production
(automobile pistons).

Castings are used virtually every where. The transport sector and heavy equipment is the predominant consumer (for farming,
construction and mining) taking up over 50% of castings produced.

A sector wise casting consumption is given below which highlights the importance of casting in any industrial set up.

• Transport : Automobile, aerospace, railways and shipping

• Heavy Equipment : Construction, farming and mining

• Machine Tools : Machining, casting, plastics molding, forging, extrusion and forming

• Plant Machinery : Chemical, petroleum, paper, sugar, textile, steel and thermal plants

• Defence : Vehicles, artillery, munitions, storage and supporting equipment

• Electrical Equipment Machines : Motors, generators, pumps and compressors

• Hardware : Plumbing industry pipes, joints, valves and fittings

• Household : Appliances, kitchen and gardening equipment, furniture and fittings

• Art Objects : Sculptures, idols, furniture, lamp stands and decorative items
Industrial Process Description
The metal casting process has been divided into the following five major operations:

• Obtaining the Casting Geometry :

The process is referred as the study of the geometry of parts and plans, so as to improve the life and quality of casting.

• Casting Patternmaking :
In pattern making, a physical model of casting, i.e. a pattern is used to make the mold. The mold is made by packing
some readily formed aggregated materials, like molding sand, around the pattern. After the pattern is withdrawn, its
imprint leaves the mold cavity that is ultimately filled with metal to become the casting.
n case, the castings is required to be hollow, such as in the case of pipe fittings, additional patterns, known as cores, are
used to develop these cavities.

• Coremaking & Molding :

In core making, cores are formed, (usually of sand) that are placed into a mold cavity to form the interior surface of the casting. Thus
the annul space between the mold-cavity surface and the core is what finally becomes the casting.
Molding is a process that consists of different operations essential to develop a mold for receiving molten metal.

• Alloy Melting and Pouring :

Melting is a process of preparing the molten material for casting. It is generally done in a specifically designated part of
foundry, and the molten metal is transported to the pouring area wherein the molds are filled.

• Casting Cleaning :
Cleaning is a process that refers to the different activities performed for the removal of sand, scale, and excess metal from
the casting.
However, all the operations may not apply to each casting method but such processes play an important role to comply
with environmental guidelines.

Molds by themselves can only have the external shape of the pattern. That is why cores are placed inside the mold to form internal
cavities. Cores are produced in a core box, which is a permanent mold, developed in tandem with the pattern. It helps in flowing the
molten metal to all sides of the cores.

Cores are supported either on core prints or by metal supports called chaplets. Generally the foundry molds are made of sand
grains bonded together to form the desired shape of the casting. Sand is used because it is cheap, resists deformation when
heated, offers a great variety of casting sizes and complexities. It also offers the added advantage of reuse of a large portion of the
sand in future molds. However pattern making, melting, cleaning, and finishing operations are essentially the same whether or not
sand molds are used in the casting process.