| PROSNA, INC. GLOBAL SOURCING |
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| We specialize in the global sourcing of custom manufactured metal parts | |
| SAND CASTING PROCESS |
| Die Castings | Investment Castings | Sand Castings |
| Casting Process Comparison Chart | ||
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| Low Cost - High Quality Sand Castings in Most Irons, Steels, and Ferrous & Non-Ferrous Alloys |
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SAND CASTING PROCESS In this process, a pattern is made in the shape of the desired part. This pattern can be made in wood, plastic, or metal. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom section, called a drag. Both solid and split patterns can have cores& inserts to complete the final part shape. Where the cope and drag separate is call the parting line. When making a pattern it is best to taper (draft) the edges, so that the pattern can be removed without breaking the edges of the mold. The pattern(s) are then packed into sand, with a binder, which helps harden the sand into a semi-permanent shape. Once the sand mold is cured, the pattern is removed, leaving a hollow space in the sand in the shape of the desired part. The pattern is intentionally made larger than the cast part to allow for shrinkage during cooling. Sand cores can then be inserted in the mold to create holes and improve the casting's net shape. Simple patterns are normally open on top and the melted metal is poured into the mold. Two piece molds are clamped together and the melted metal is poured into an opening called a gate. If necessary, vent holes will be created to allow hot gases to escape during the pour. The pouring temperature of the metal should be a few hundred degrees higher than the melting point of the metal to assure good fluidity, thereby avoiding premature cooling, which will cause voids and porosity. When the metal cools, the sand is removed and the metal part is ready for secondary operations, such as machining and finishing. Sand casting is the least expensive of all of the casting processes, and provides the least dimensional accuracy. |
| Ductile Iron Gray Iron Steel Stainless Steel related Alloys |
| ADVANTAGES | DISADVANTAGES |
| Least Expensive
Casting Process Castings Can be up to Several Tons Less Expensive than Machining Shapes from Bar Stock Can Cast Basic Shapes Can be Used with most Pourable Metals and Alloys Many parts can be used as Cast |
Can Only Cast Basic
Part Shape Castings Require Secondary Machining Rough Surface Finish, RMS 300-900 |
| SECONDARY
OPERATIONS Conventional or Precision CNC Machining Heat Treating Surface Finishing - Etching, Vibration, Grinding, and Polishing Plating - Anodizing - Painting - Powder Coating Certified Metallurgical and Non-Destructive Testing |
| Tel 219-924-1252 | PROSNA, INC. | www.prosna.com |
| Fax 219-924-1260 | 530 Superior Avenue | info@prosna.com |
| Munster, Indiana 46321 USA | ||
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